Design of Scalable, Next-Generation Thick Electrodes: Opportunities and Challenges

Lithium-ion battery electrodes are on course to benefit from current research in structure re-engineering to allow for the implementation of thicker electrodes. Increasing the thickness of a battery electrode enables significant improvements in gravimetric energy density while simultaneously reducing manufacturing costs. Both metrics are critical if the transition to sustainable transport systems is to be fully realized commercially. However, significant barriers exist that prevent the use of such microstructures: performance issues, manufacturing challenges, and scalability all remain open areas of research. In this Perspective, we discuss the challenges in adapting current manufacturing processes for thick electrodes and the opportunities that pore engineering presents in order to design thicker and better electrodes while simultaneously considering long-term performance and scalability.