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Powder to Electrode™ Dry Coating Technology: A Deep Dive

AM Batteries has pioneered a revolutionary dry, roll-to-roll electrode manufacturing process called Powder to Electrode™, providing turn-key solutions from raw materials to rolls of electrode while eliminating toxic solvents like NMP, energy-intensive ovens, and complex solvent recovery systems. Our technology reduces manufacturing costs, improves battery performance, and enables compatibility with a wide range of chemistries, including next-generation systems.

We Invest In The Companies Of The Future Home V3 Hero BG - Invstor X Framer Template

Powder to Electrode™ Dry Coating Technology: A Deep Dive

AM Batteries has pioneered a revolutionary dry, roll-to-roll electrode manufacturing process called Powder to Electrode™, providing turn-key solutions from raw materials to rolls of electrode while eliminating toxic solvents like NMP, energy-intensive ovens, and complex solvent recovery systems. Our technology reduces manufacturing costs, improves battery performance, and enables compatibility with a wide range of chemistries, including next-generation systems.

Core Innovations

Dry Powder Mixing

Materials: Compatible with NMC, NCA, LFP, LCO, graphite, SiOx/SiC
Binder Flexibility: Supports PFAS and non-PFAS binders
Process: Energy-efficient, non-agglomerating powders, suitable for continuous feeding and inline control

Precision Dry Powder Coating via Dry Deposition

Edge Control: Good edge fidelity for electrode design
Layering: Supports thick, thin, gradient, and dual-side designs
Microstructure: Enables low-tortuosity electrodes for superior ionic/electronic transport

Tunable Compression & Calendering

Electrode Range: ~30-200μm+
Tortuosity: Lower than slurry, promoting better rate and cycling performance
Customization: Optimized for energy or power density

SEM Image
EPL Dry Electrode (Edge View)

SEM Image (Cross-section, BSD) Sample Density: 3.79 g/cm³

Electrochemical & Structural Advantages

Rate Capability

High power due to fast ion transport and low internal resistance

Cycle Life

Stable cycle life from uniform structure and over 1000 cycles comparable to wet

Wetting & Activation

Rapid electrolyte wetting due to open pore structure

Electrochemical Testing – Dry vs Wet

Electrochemical Testing – Dry vs Wet

Discharge rate test comparing dry vs. wet electrode with identical formulation
Charge rate test comparing dry vs. wet electrode with identical formulation
Cycle life test of dry vs. wet electrode with identical formulation

Chemistries Supported

Cathodes

NMC (all ratios), LCO, LFP, NCA

Anodes

Graphite, SiOx/SiC

Future

Sodium-ion, solid-state, conversion-type materials

Advantages Over Competing Dry Coating Technology