FABRICATION STRATEGIES FOR MODERN BATTERY TECHNOLOGIES: A COMPARATIVE REVIEW

Abstract

The expansion of electrification, renewable energy systems, and portable technologies has increased demand for rechargeable batteries with improved performance, safety, and manufacturability. Although substantial progress has been achieved in battery materials, fabrication processes play an equally critical role in determining electrode microstructure, interfacial stability, ionic transport, and overall cell reliability. This review presents a fabrication-centred comparative analysis of major battery technologies, examining how processing strategies influence electrochemical behaviour and manufacturing feasibility. General principles of electrode preparation, electrolyte formulation, and cell assembly are first outlined, followed by a discussion of fabrication requirements specific to different battery chemistries. Attention is given to lithium-ion, solid-state, metal–air, and flow batteries, highlighting how variations in processing conditions affect microstructural evolution, defect formation, and transport pathways. Comparative evaluation identifies key cross-cutting challenges in battery manufacturing, including slurry homogeneity, binder migration, interface stability, moisture sensitivity, and scalability constraints. Emerging fabrication approaches are also examined as potential pathways for improving performance and manufacturing efficiency. Unlike many existing battery reviews that focus primarily on electrochemical materials or device performance, this work emphasizes the role of manufacturing science in enabling practical battery deployment. By systematically linking fabrication parameters with transport behaviour, structural integrity, and industrial scalability across multiple battery chemistries, the review provides a framework for guiding the development and large-scale production of next-generation energy storage systems.