This module covers the theoretical fundamentals as well as the practical understanding of the calendering process in the manufacturing of lithium-ion battery electrodes with lithium iron phosphate (LFP) cathodes. The calendering step is one of the most important processes in electrode production, as it compacts the previously coated and dried electrode to a defined thickness and density. This densification significantly influences the porosity, electrical conductivity, mechanical stability, and the long-term electrochemical performance of the resulting cell. The compaction step also plays a growing role in emerging technologies such as all-solid-state batteries (ASSB), where achieving dense, low-porosity structures is essential for reliable ion transport across solid electrolytes.

The session combines theoretical fundamentals with practical modeling of compaction mechanics. Participants gain insight into how densification parameters affect the electrode microstructure and how these changes translate into functional properties. Special attention is given to structure-property relationships, the role of porosity and density in cell performance, and the comparison between lithium-ion and ASSB compaction requirements. The course also examines different compaction methods, contrasting the roll-based calendering process used here with alternative approaches such as uniaxial and isostatic pressing.

The practical component covers the modeling of compaction mechanics, the analysis of structure-property relationships, and the evaluation of how process parameters influence the resulting electrode density and porosity.

Learning Objectives

  • Participants understand the basic physical and mechanical mechanisms of electrode calendering and can describe how densification influences porosity, conductivity, and cell performance in both lithium-ion and all-solid-state batteries.
  • Participants can describe basic compaction mechanics and interpret selected structure–property relationships to explain how process parameters affect electrode density, porosity, and quality.
  • Participants can compare different compaction methods, including calendering, uniaxial pressing, and isostatic pressing, and assess their suitability for conventional and next-generation battery technologies.