Proceedings of the XMO Industrial Seminar 2026: Excellence in Manufacturing and Operations
Keywords
Cold spray; dry electrode; lithium-ion battery; LFP cathode; solvent-free manufacturing
Tracks
CONVERGENT MANUFACTURING
DOI
10.5703/1288284318683
Abstract
Conventional lithium-ion battery cathodes are typically fabricated through slurry-based processing, which requires organic solvents, coating, drying, and post-processing steps. Although this process is widely used, the use of toxic solvents such as N-methyl-2-pyrrolidone and the long drying process increases manufacturing complexity, energy consumption, and environmental burden. In this work, a cold spray-based solvent-free process was investigated as a one-step route for fabricating lithium iron phosphate cathode layers. A representative cathode composite powder consisting of lithium iron phosphate, carbon black, and polyvinylidene fluoride was prepared with a weight ratio of 10:1:1. To improve powder feeding behavior, 0.1 wt% fumed silica was added, and the composite feedstock was sequentially pretreated using a Cole-Parmer High-Energy Ball Mill. The prepared powder was directly deposited onto aluminum foil using a cold spray system with compressed air at 100 psi and 300°C. The deposited cathode layer was examined to evaluate coating formation, morphology, and preliminary battery applicability. Optical observations confirmed that an LFP-based composite layer could be directly formed on the aluminum current collector without slurry preparation or a drying step. A Li metal half coin cell was then assembled using the cold-sprayed cathode to assess its electrochemical functionality. Although the initial electrochemical performance was limited under the current fabrication conditions, the half-cell test showed measurable electrochemical activity, confirming the preliminary feasibility of the cold-sprayed cathode as a battery electrode. These results suggest that cold spray can serve as a potential solvent-free manufacturing route for dry cathode fabrication. Further optimization of powder flowability, electrode thickness, deposition uniformity, fabrication environment, and post-deposition densification is expected to improve the electrochemical performance of cold-sprayed cathodes.
Development of a Cold Spray-Based Dry Manufacturing Process for LFP Battery Cathode
Conventional lithium-ion battery cathodes are typically fabricated through slurry-based processing, which requires organic solvents, coating, drying, and post-processing steps. Although this process is widely used, the use of toxic solvents such as N-methyl-2-pyrrolidone and the long drying process increases manufacturing complexity, energy consumption, and environmental burden. In this work, a cold spray-based solvent-free process was investigated as a one-step route for fabricating lithium iron phosphate cathode layers. A representative cathode composite powder consisting of lithium iron phosphate, carbon black, and polyvinylidene fluoride was prepared with a weight ratio of 10:1:1. To improve powder feeding behavior, 0.1 wt% fumed silica was added, and the composite feedstock was sequentially pretreated using a Cole-Parmer High-Energy Ball Mill. The prepared powder was directly deposited onto aluminum foil using a cold spray system with compressed air at 100 psi and 300°C. The deposited cathode layer was examined to evaluate coating formation, morphology, and preliminary battery applicability. Optical observations confirmed that an LFP-based composite layer could be directly formed on the aluminum current collector without slurry preparation or a drying step. A Li metal half coin cell was then assembled using the cold-sprayed cathode to assess its electrochemical functionality. Although the initial electrochemical performance was limited under the current fabrication conditions, the half-cell test showed measurable electrochemical activity, confirming the preliminary feasibility of the cold-sprayed cathode as a battery electrode. These results suggest that cold spray can serve as a potential solvent-free manufacturing route for dry cathode fabrication. Further optimization of powder flowability, electrode thickness, deposition uniformity, fabrication environment, and post-deposition densification is expected to improve the electrochemical performance of cold-sprayed cathodes.