A team of scientists in South Korea has developed an innovative method for producing high-capacity battery electrodes, inspired by the same spray-drying process used to make instant coffee. The breakthrough could play a key role in advancing next-generation battery technologies such as solid-state and lithium-sulfur batteries.
Battery electrodes are typically produced by mixing active materials, conductive additives, and binding agents. This can be done using a wet method with solvents, or a dry method using solid powders. While the dry process is more sustainable and potentially delivers higher energy density, it has struggled with inconsistent mixing — a major hurdle for commercial scaling.
To overcome this, researchers adopted a spray-drying technique commonly used in the food industry. By spraying a liquid mixture into a heated chamber, the solvent evaporates rapidly, leaving behind a finely blended powder. This powder is then used to create dry electrodes with a more uniform structure and improved performance.
In testing, these dry electrodes achieved a surface capacity of around 7 mAh/cm² — significantly higher than the 2–4 mAh/cm² seen in current commercial electrodes. The team also uncovered new insights into factors driving battery degradation, beyond the typical wear from charging cycles.
Senior researcher Jihee Yun confirmed that the team is now focused on scaling the technology for industrial use: “Through further research, we plan to reduce production costs, improve mass production capabilities, and enhance technology maturity for subsequent transfer to companies.”
The innovation aligns with wider global efforts to improve battery sustainability and efficiency. In the US, startup Re/cell is recycling lithium from end-of-life Tesla batteries for use in drones and unmanned vehicles. Meanwhile, engineers are developing manufacturing techniques that allow EV batteries to charge more quickly in cold weather — addressing a known challenge for EV adoption in colder climates.
For hot regions, where high-performance and thermally stable batteries are critical for EVs operating in extreme heat, advances like these could influence future import strategies, localisation opportunities, and grid storage solutions.
