What active materials and custom formulations do you support for battery electrode manufacturing?

We offer bespoke customization for a vast array of materials. For Lithium-Ion, we support NCM, NCA, LFP, LCO, Silicon-Carbon, and Lithium metal. For Sodium-Ion, we process NVP, Hard Carbon, and Prussian Blue. Our custom formulation service allows you to dictate exact active material ratios, conductive agent blends, and binder networks.

Do you provide both wet and dry electrode coating, and what are the supported mass loadings?

Yes, we provide both traditional wet-slurry coating and next-generation solvent-free dry electrode processing. Our wet coating supports precise mass loadings from 5 to 30 mg/cm2. Our dry electrode roll-pressing enables ultra-high mass loadings from 20 to 60 mg/cm2 without binder migration, perfect for solid-state batteries.

Can you customize the current collectors and accommodate specific compaction densities?

Absolutely. We customize the entire architecture by coating on standard foils, carbon-coated foils, or microporous perforated foils. Furthermore, we dynamically adjust the compaction density during the calendering process to suit the brittleness of your specific materials, ensuring optimal volumetric energy density.

Electrode Sheets

Custom Battery Electrode Sheets & Advanced Coating Services

Bridging the critical gap between material synthesis and full-cell prototyping, ATOMFAIR provides a comprehensive, scalable customization platform for advanced battery electrode sheets. Whether you require standard baseline validation or cutting-edge architectural design, we support everything from traditional wet-slurry casting to next-generation solvent-free dry electrode roll-pressing. Utilizing industrial-grade pilot lines equipped with precise transfer and slot-die coating technologies, we offer unparalleled control over mass loading, specific capacity, and current collector integration. With specialized capabilities in bespoke formulation design, multi-material blending, and composite structures for All-Solid-State Batteries (ASSB), our electrode manufacturing accelerates your transition from lab-scale discovery to commercial viability.

Show Customization Matrix & Capabilities

I. Comprehensive Material Customization Matrix

We maintain an extensive inventory of active materials and support custom mixing for a vast array of established and emerging electrochemical systems. If your material is not listed, we also accept client-supplied powders for exclusive toll coating.

Battery System	Supported Cathode Materials	Supported Anode Materials
Lithium-Ion (LIB)	Lithium Nickel Cobalt Manganese Oxide (NCM: 811, Ni90, Ni95, 622, 613, 532), Lithium Nickel Cobalt Aluminum Oxide (NCA), Lithium Iron Phosphate (LFP), Lithium Manganese Iron Phosphate (LMFP), Lithium-Rich Manganese-Based Oxide (LRMO / LLO), Lithium Cobalt Oxide (LCO), Lithium Nickel Manganese Spinel Oxide (LNMO, High-Voltage 5V)	Artificial & Natural Graphite, Mesocarbon Microbeads (MCMB), Silicon-Carbon Composites (Si-C / SiOx), Pure Nano-Silicon, Lithium Titanate (LTO, Li4Ti5O12), Tin Dioxide-based (SnO₂), Ultra-Thin Lithium Metal Foil
Sodium-Ion (SIB)	Layered Transition Metal Oxides (O3-type, P2-type, NFM, NMO), Sodium Vanadium Phosphate (NVP, Na3V2(PO4)3), Sodium Iron Pyrophosphate (NFPP), Sodium Iron Sulfate (NFS), Prussian Blue Analogs (PBA) / Prussian White	Hard Carbon (HC), Soft Carbon (SC), Red Phosphorus-Carbon (P/C) Composites, Alloy Anodes (Bismuth Bi, Antimony Sb), Sodium Metal Foils
Zinc-Ion (ZIB) & Aqueous	Manganese Dioxide (MnO₂), Zinc Manganese Oxide (ZnMn₂O₄), Vanadium Pentoxide (V₂O₅), Vanadium Disulfide (VS₂), Zinc Hexacyanoferrate (ZnHCF)	Metallic Zinc Foils, 3D Porous Zinc Structures, Zinc-Alloy Foils
Blended & Hybrid Architectures	Precision blending configurations (e.g., LFP + LMFP for voltage plateau tuning, NCM + LCO for compaction optimization)	Graphite + SiOx/Nano-Silicon blending with tailored buffer binders (PAA/CMC/SBR networks)
Solid-State (ASSB) & Beyond	Composite cathodes integrated with Solid Electrolytes (Sulfide/Oxide/Halide), Sulfur-Carbon matrices (Li-S) with specific electrocatalysts, Lithium-Air electrodes	Pre-lithiated binder-free architectures, Solid-State coated Lithium Foils

II. Specialized Architectural & Formulation Capabilities

Beyond standard material dispersions, ATOMFAIR provides advanced formulation design and architectural electrode engineering designed to solve complex thermodynamic and kinetic bottlenecks in modern battery research:

Bespoke Formulation Design

Clients are not restricted to generic mass ratios (e.g., 8:1:1 or 9:0.5:0.5). We tailor the exact proportions of active materials, conductive networks (mixing Super P, SWCNTs, MWCNTs, or Graphene), and advanced binder systems (PVDF, PTFE, PAA, CMC/SBR). Furthermore, we dynamically adjust the target thickness and compaction density based on the specific brittleness of your active material. This precision prevents the pulverization of delicate crystalline structures (like certain polyanions or hard carbons) during the calendering process, ensuring optimal volumetric energy density without sacrificing mechanical integrity.

Multi-Material Blended Coating

Maximizing cell performance often requires synergistic material combinations. We utilize high-shear planetary mixing to precisely blend active materials with differing particle size distributions (PSD) and tap densities. Whether blending Graphite with Silicon suboxides (SiOx) to balance capacity and volume expansion, integrating specific chemical ratios of catalysts for Li-S systems, or mixing LFP with LMFP to modulate voltage plateaus, our process ensures zero phase separation and homogeneous dispersion.

Dedicated Solid-State Battery (SSB) Electrodes

Manufacturing electrodes for All-Solid-State Batteries (ASSB) introduces severe interface challenges. We provide specialized composite electrode coating where Solid Electrolyte (SE) powders (such as Argyrodites, LLZO, or LATP) are co-integrated directly into the cathode matrix. This establishes a robust 3D ionic percolation network. Furthermore, our solvent-free dry electrode capability eliminates the chemical degradation of sensitive sulfide-based solid electrolytes typically caused by traditional NMP solvents.

III. Process Engineering: Wet vs. Dry Electrode Manufacturing

We deploy both transfer coating and high-precision slot-die coating equipment, available in continuous roll-to-roll or intermittent (patch) configurations, to match your desired format.

Traditional Wet Slurry Coating

Loading Capability: 5 to 30 mg/cm²
Advantages: The mature industry standard ensuring exceptional morphological uniformity for low-to-medium mass loadings. Wet coating provides intimate contact between active particles, conductive agents, and the current collector, making it the perfect control baseline for high-rate kinetic testing and standard consumer/automotive cell prototyping.

Next-Generation Solvent-Free Dry Electrode

Loading Capability: 20 to 60 mg/cm²
Advantages: Represents the bleeding edge of high-energy-density manufacturing. By utilizing PTFE mechanochemical fibrillation instead of toxic solvents, the dry process completely eliminates the thermal drying phase. This prevents “binder migration” (which causes active layer delamination in thick electrodes), enables ultra-high mass loading (>5 mAh/cm²), and is highly compatible with moisture/solvent-sensitive solid-state materials.

IV. Advanced Current Collector Configurations

Electrode adhesion and internal resistance are heavily dictated by the substrate. We provide custom coating onto a variety of specialized foils to mitigate interfacial impedance and accommodate volume expansion:

Standard Foils: High-purity Aluminum (Al) and Copper (Cu) foils.
Carbon-Coated Foils: Utilizes a nanometer-scale conductive carbon primer to drastically lower contact resistance, protect the foil from highly corrosive electrolytes, and enhance binder adhesion—especially critical for LFP and high-voltage LNMO systems.
Microporous / Perforated Foils: Engineered for high-stress architectures (like Silicon-Carbon anodes or pure Lithium metal), providing physical anchoring points for the electrode matrix to prevent delamination during severe volume expansion, while facilitating rapid 3D ion diffusion.
Specialty Substrates: Titanium foil (highly stable for aqueous ZIBs), Stainless Steel mesh, and Nickel foam for specialized flow or supercapacitor applications.

Featured Custom Electrode Formats

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