This study presents a detailed review of the process parameters and their impact on the production of semidry coated lithium‐ion battery (LIB) electrodes. A key focus is the dispersion and granulation extrusion process, where essential scientific correlations are established to enable the production of highly solvent reduced pellets. Furthermore, the concept of coatability is introduced via a newly defined degree of saturation, which quantifies the relationship between solvent volume and electrode pore structure. Experimental validation demonstrated that anode and cathode formulations were optimally coatable at a degree of saturation between 0.6 and 0.67. Additionally, optimized extrusion temperatures and solvent compositions enhanced adhesion and minimized coating defects. By fine tuning the process parameters, including the coating temperatures (20°C for anodes, 70°C for lithium iron phosphate (LFP) cathodes), the mass loading deviation remained within the industry standard of 2% for both high‐power and high‐energy electrodes. These findings provide a foundation for adapting new material systems to the semidry process, paving the way for more sustainable and cost‐effective LIB manufacturing.
Reinkensmeyer et al. (Sun,) studied this question.