Capillary-Bridged Slurry Engineering Enables Scalable Lithium Battery Electrodes Achieving 27 mAh cm^–2

Increasing electrode mass loading is an effective route to improving cell-level energy density without altering material chemistry, yet conventional slurry-casting fabrication is constrained by drying-induced heterogeneities that impair structural integrity and electrochemical performance. Here, we present a capillary-bridged slurry engineering strategy that enables scalable fabrication of high-mass-loading electrodes with uniform composition and robust structure. Introducing a trace amount of an immiscible secondary solvent generates capillary bridges, forming percolated particle networks that suppress directional migration of electrode components during drying. Applied to Ni-rich cathodes, this method achieves uniform through-thickness composition and redox homogeneity at thicknesses exceeding 400 μm, delivering areal capacities up to 27 mAh cm^–2. It also enhances manufacturing reliability by ensuring thickness uniformity over large areas, reducing scrap losses, and increasing electrode production yield, thereby lowering cell-level costs. This approach is compatible with existing slurry-casting lines, offering a scalable, cost-effective pathway to energy-dense battery electrodes.