A team at Worcester Polytechnic Institute (WPI), led by Professor Yan Wang, has developed an innovative, solvent-free process for creating lithium-ion battery electrodes that charge significantly faster than existing options. This new manufacturing technique, detailed in the journal Joule, replaces the traditional slurry-based method that relies on harmful solvents and extensive drying, making it more environmentally friendly and cost-effective. Wang’s technique involves mixing dry powders that adhere to a metal substrate through electrostatic charging, followed by heating and compression, eliminating the need for lengthy solvent recovery and drying processes. This method can potentially reduce production costs by 15% and cut energy use in manufacturing by around 47%. The resulting electrodes can achieve 78% charge capacity in just 20 minutes, addressing the slow charging issues of conventional batteries. Wang, who has previous experience in battery recycling through his company Ascend Elements, aims to further improve lithium-ion battery sustainability. The research has received funding from the Department of Energy and partnerships with several institutions. WPI has filed a patent application for this new technology, and Wang has co-founded AM Batteries Inc. to advance this solvent-free manufacturing approach with industry collaborators.