En
期刊文章
文章精选
当期目录
过刊浏览
高被引
高下载
特邀文章
专刊合集
待刊文章
Volume 109
您当前的位置：首页 > 期刊文章 > 当期目录 > Volume 109
Modelling of dry manufacturing of LFP cathode filaments with twin-screw extruder using the Discrete Element Method (Open Access)
Kaize Shi a, Ali Hassanpour b, Meisam Babaie a, Masoud Jabbari a *
a School of Mechanical Engineering, University of Leeds, Leeds, LS2 9JT, UK
b School of Chemical and Process Engineering, University of Leeds, Leeds, LS2 9JT, UK
10.1016/j.partic.2025.11.020
Volume 109, February 2026, Pages 1-11
Received 24 September 2025, Revised 10 November 2025, Accepted 28 November 2025, Available online 11 December 2025, Version of Record 15 December 2025.
E-mail: m.jabbari@leeds.ac.uk
Highlights

• DEM simulation of solvent-free (dry) electrode manufacturing.

• Investigation of process conditions on battery filament fabrication.

• Analysing pore-scale properties of filaments.


Abstract

Material extrusion is a key step in the solvent-free fabrication of lithium-ion battery (LIB) electrodes, offering reduced costs and environmental impact compared to slurry-based methods. While discrete element method (DEM) based mesoscopic models have been used to study twin-screw extrusion, the microstructural characterisation of extrudates immediately after nozzle exit remains unexplored. In this study, a series of DEM simulations were conducted to perform a sensitivity analysis of the microstructure and electrochemical performance-related parameters of extruded electrode filaments by varying the feeding rate and feeding mode, screw rotational speed, and particle cohesion. Furthermore, this work addresses the previously unexamined phenomenon of filament expansion during extrusion. By introducing the Augmented Dickey-Fuller (ADF) method, the study also provides the first analysis of the temporal dynamic stability of filament quality during the dry electrode manufacturing extrusion process. The results show that increasing the screw speed from 100 to 500 RPM reduces porosity by 10 % and limits expansion, while lower speeds improve consistency in electrode quality. A novel approach to quantifying dynamic behaviour is proposed, offering insights for optimising solvent-free electrode manufacturing.

Graphical abstract
Keywords
Lithium-ion batteries; Dry manufacturing; Discrete element method; 3D printing; Twin-screw extruder
文章导读