Battery manufacturers are exploring dry electrode manufacturing to reduce dependence on solvent-based slurry coating and its associated drying and recovery operations. However, a successful dry electrode is not simply a conventional coating made without solvent. The binder must distribute through a powder blend, establish sufficient particle-to-particle cohesion, attach the resulting film to a current collector, and preserve conductive and ion-transport pathways throughout densification and battery cycling.
Polytetrafluoroethylene (PTFE) remains a widely used reference because mechanical shear can produce fibrils that support self-standing electrode films. Replacing this fluorinated binder introduces a demanding materials-selection problem: an alternative must provide comparable structural function without compromising adhesion, porosity, processing throughput, or electrochemical stability. Polyolefin- and other thermoplastic-based systems offer promising routes, but their activation mechanisms and processing requirements differ from PTFE.
This advanced expert-led training concentrates on the chemistry and engineering decisions behind PFAS-free dry electrode development. Participants will examine binder selection, active-material and conductive-additive distribution, powder conditioning, mixing intensity, film consolidation, current-collector bonding, and qualification testing. Industrially relevant examples will draw on lithium iron phosphate and nickel-rich cathodes, with an examination of graphite-anode constraints.
The training connects material properties to processing conditions and final electrode performance, helping professionals design better-controlled experiments, compare alternative binder technologies, and evaluate their suitability for industrial dry electrode production.
What Problem This Training Solves
PFAS-Free Binder Selection: Finding practical PTFE alternatives for cohesive dry electrodes.
Poor Powder Uniformity: Reducing agglomeration, segregation and uneven binder distribution.
Weak Electrode Integrity: Addressing cracking, poor cohesion and current-collector adhesion.
Performance Tradeoffs: Balancing electrode loading, porosity, conductivity and mechanical strength.
Processing Uncertainty: Establishing reliable mixing, consolidation and calendering conditions.
Why Attend This Training?
Assess PFAS-Free Binders: Compare polymer chemistries, bonding mechanisms and electrode compatibility.
Improve Powder Formulations: Optimize binder loading, conductive additives and powder distribution.
Refine Dry Processing: Control mixing, film formation, calendering and lamination parameters.
Enhance Electrode Performance: Improve mechanical integrity, conductivity and cycling stability.
Strengthen Formulation Decisions: Apply practical testing methods to evaluate and qualify dry electrodes.
Who Should Attend?
This training is designed for professionals involved in battery electrode materials, formulation, processing and performance evaluation, including:
Battery Materials Scientists and Electrochemists
Electrode Formulation Chemists and Polymer Binder Researchers
Lithium-Ion Battery R&D and Product Development Engineers
Battery Electrode Manufacturing and Process Engineers
Polymer and Specialty Chemical Technical Development Teams
Battery Raw Material and Conductive Additive Suppliers
Cell Development, Characterization and Quality Engineers
Technical Managers and Research Leaders in Energy Storage
Training Outline
Dry Electrode Manufacturing: Material and Process Requirements
PFAS-Free Binder Chemistry and Alternative Formulation Strategies
Powder Formulation, Mixing and Binder Distribution
Dry Film Formation, Calendering and Current-Collector Bonding
Electrode Characterization, Performance and Qualification
Applied Formulation Examples and Industrial Development Decisions
Q&A Session With Expert To Clear Doubts
Practical Outcomes
You will finish the training with a clearer understanding of how to:
Screen PFAS-free polymer binder technologies for a defined electrode application.
Construct meaningful dry powder formulation comparisons.
Identify suitable mixing, film-forming and calendering conditions.
Select mechanical, structural and electrochemical tests for electrode qualification.
Evaluate binder-performance tradeoffs and production-readiness evidence.
Advance Your Expertise in Next-Generation Battery Electrode Manufacturing
Develop the technical understanding needed to evaluate emerging PFAS-free binder technologies, optimize solvent-free powder processing and connect electrode formulation decisions to measurable battery performance. Register Now
