<2026> Dry Electrode Process Technology for Secondary Batteries: Development Trends and Market Outlook (~2035)

<2026> Dry Electrode Process Technology for Secondary Batteries - Development Trends and Market Outlook (~2035)

Recently, the dry electrode process has emerged as a key next-generation battery manufacturing technology in the global battery industry. Interest in dry electrode technology is rapidly growing across various battery applications, including EVs, ESSs, all-solid-state batteries, and sodium-ion batteries (SIBs). Global battery manufacturers increasingly recognize securing dry electrode technology as a critical factor in strengthening their future competitiveness.

The dry electrode process manufactures electrodes by directly mixing active materials, conductive additives, and binders without the use of solvents, followed by processes such as rolling, pressing, and lamination. By eliminating the drying process and NMP recovery equipment, the technology is estimated to reduce process energy consumption by approximately 20–40% and capital expenditures (CAPEX) for manufacturing facilities by approximately 15–30%. In addition, shorter production lines and reduced factory space requirements make the process highly advantageous for large-scale battery manufacturing.

Tesla is one of the leading companies in dry electrode technology. Tesla began securing dry electrode technology through its acquisition of Maxwell Technologies in 2019 and has since applied the dry electrode process as a core technology in the development of its next-generation 4680 cylindrical battery cells. Initially, a hybrid approach combining a dry anode with a wet cathode was primarily adopted. However, Tesla appears to have addressed the application of the dry process to cathodes by introducing a composite binder system, as disclosed in its recent patent US2025/0364562. In this approach, polymer binders such as PVDF, PEO, and PE are blended with PTFE. These additional polymer binders are believed to coat the surface of the active material, forming a protective layer that prevents direct interaction between PTFE and the electrode active material.

In particular, 4680 battery cells require significantly thicker electrodes and higher areal loading than conventional cylindrical cells. They also employ a tabless structure to achieve high power output and high energy density, making the advantages of dry electrode technology directly relevant to their performance and manufacturing requirements.

Dry electrode technology is even more significant in the field of all-solid-state batteries. Many industry experts believe that, as all-solid-state batteries move toward commercialization, the dry electrode process is likely to become an essential manufacturing platform rather than merely an optional technology.

However, solid electrolytes used in all-solid-state batteries, including sulfide-, oxide-, and halide-based electrolytes, are sensitive to moisture and organic solvents, which can cause interfacial reactions or performance degradation during wet slurry processing. Sulfide-based electrolytes, in particular, require special handling during manufacturing due to the risk of generating hydrogen sulfide (H₂S) upon exposure to moisture.

For this reason, dry-based manufacturing methods such as dry mixing, dry film formation, and dry lamination offer significant advantages in all-solid-state battery production. Since the dry electrode process does not use solvents, it can help maintain the stability of solid electrolytes while improving particle-to-particle contact and reducing interfacial resistance.

One of the major technical challenges facing all-solid-state batteries is achieving sufficient interfacial contact between the cathode and solid electrolyte, as well as between the anode and solid electrolyte. Recent studies have reported that dry co-rolling and hot pressing can improve particle contact and reduce porosity, thereby enabling strong electrochemical performance. In fact, dry-processed all-solid-state batteries have demonstrated high energy densities exceeding 300 Wh/kg and cycle life of several hundred charge-discharge cycles, highlighting their potential for commercialization.

In addition, as all-solid-state batteries inherently involve high manufacturing costs, the cost-saving benefits of the dry electrode process become even more important. Eliminating drying equipment, simplifying manufacturing processes, and reducing energy consumption can significantly lower overall production costs. These benefits are expected to play a key role in ensuring the economic viability of future mass production of all-solid-state batteries.

Major battery and automotive companies, including Toyota, Nissan, LG Energy Solution, Samsung SDI, and CATL, are also actively developing dry electrode technologies for all-solid-state batteries and other next-generation batteries. In particular, around 2030, when the commercialization of all-solid-state batteries is widely anticipated, the dry electrode process is likely to become a de facto standard manufacturing platform.

This report aims to provide an outlook on the current status and near-term future of dry electrode processing by examining key technical topics, including the need for carbon-neutral process development in the rechargeable battery industry, challenges associated with conventional wet processes, and current issues in dry electrode processing. It also provides information on the latest dry electrode process development trends among rechargeable battery industry players, as well as recent developments in all-solid-state battery technologies across a wide range of companies.

Strong Points of This Report

• (1) Comprehensive technical coverage of the background and development of dry electrode processes
• (2) Detailed explanations of different types of dry electrode processes and key issues associated with electrode manufacturing
• (3) In-depth comparison of the advantages and disadvantages of dry and wet processes, including their application to battery cells
• (4) Detailed technical coverage of the application of dry electrode processes to next-generation all-solid-state batteries
• (5) Detailed information on development trends among domestic and global companies involved in electrode processing, materials, and manufacturing equipment
• (6) Coverage of government-supported dry electrode research projects by country, including their key objectives and activities
• (7) Market outlooks for dry electrode processes from major research firms