Model‐driven Manufacturing of High‐Energy‐Density Batteries: A Review

Abstract The rapid advancement in energy storage technologies, particularly high‐energy density batteries, is pivotal for diverse applications ranging from portable electronics to electric vehicles and grid storage. This review paper provides a comprehensive analysis of the recent progress in model‐driven manufacturing approaches for high‐energy‐density batteries, highlighting the integration of computational models and simulations with experimental manufacturing processes to optimize performance, reliability, safety, and cost‐effectiveness. We systematically examine various modeling techniques, including electrochemical, thermal, and mechanical models, and their roles in elucidating the complex interplay of materials, design, and manufacturing parameters. The review also discusses the challenges and opportunities in scaling up these model‐driven approaches, addressing key issues such as model validation, parameter sensitivity, and the integration of machine learning and artificial intelligence for predictive modeling, process optimization, and quality assurance. By synthesizing current research findings and industry practices, this paper aims to outline a roadmap for future developments in model‐driven manufacturing of high‐energy density batteries, emphasizing the need for interdisciplinary collaboration and innovation to meet the increasing demands for energy storage solutions.