Additive Solutions for Cathode, Anode, and Separator Processing

Lithium-ion battery production involves several carefully controlled steps. Cathode and anode materials are transformed from raw powders into thin electrode films through processes such as mixing, coating, drying, pressing, and cutting before being assembled into complete battery cells. As cathode, anode, and separator manufacturers work to improve efficiency and consistency, additive technology is becoming an increasingly important lever for better dispersion, lower and more manageable viscosity, improved wetting, and stronger coating quality. BASF is expanding its formulation expertise into this space with a growing portfolio of additives designed to support battery applications beyond its traditional coatings business.

Additive Solutions for Cathode, Anode, and Separator Electrode Manufacturing

As battery manufacturers scale production, slurry processing is becoming one of the most important levers for manufacturing efficiency, coating quality, and process consistency for optimizing electrochemical performance. Across cathode, anode, and separator applications, the market continues to focus on the same core challenges: maintaining stable dispersions, increasing solids loading, managing viscosity, improving wetting, reducing foam, and minimizing coating defects. BASF is applying its formulation expertise to these needs with a battery-focused offering designed to support better slurry control and more robust electrode manufacturing performance.

Cathode electrode

The development of next-generation electrodes is key for advancing lithium-ion battery performance. In cathode electrode manufacturing, critical needs include improved dispersion stability, reduced settling, and crack prevention in solvent-based slurry systems. The identified CGPS additives include CGPS 313D8, CGPS 513, and CGPS 277B, which support improved milling efficiency, reduced slurry viscosity, and enhanced storage stability in LFP and LMFP systems. In addition, CGPS 839 improves coating-layer flexibility and helps prevent cracking in both LFP and NCM formulations. The source material states that these dispersant additives help stabilize conductive carbon particles, give cathode manufacturers better dispersion, more manageable viscosity, and more robust, scalable coating quality and reduce the propensity for coating cracks.

Additives for Separator Layer

Separator processing remains another clear opportunity area, especially where the need is PVDF particle dispersion and slurry stability. For this market need, CGPS 310W and CGPS 277A function as premium dispersants for PVDF powder and can also support separator formulations in water-based PVDF and PMMA systems. Based on our technical lab work, key wetting agent additives are CGPS 666W, CGPS 612W, and CGPS 610W which provide defect free separator films.

Another relevant opportunity is the dispersion of Al₂O₃ and boehmite particles in separator coating systems, where stable slurry behavior, controlled viscosity, and uniform particle distribution are critical for coating quality and separator performance. For these mineral-based separator slurries, CGPS 820W, CGPS 700W, and CGPS 800W are recommended dispersant options to support improved particle wetting, dispersion stability, and processing consistency.

Anode electrode

Another important market need is better wetting and defect control in anode-related coating systems. For this need, BASF reference material identifies CGPS 610W, CGPS 612W, and CGPS 613W as relevant wetting-agent options. Here, the CGPS 612W is silicone-based and includes an antifoam feature, while CGPS 613W is a non-silicone option that also includes antifoam features.

A key market need is improving conductive material dispersion in water-based systems, particularly where manufacturers are trying to increase carbon-black loading while preserving stability and process control. For this application area, the CGPS dispersant additives highlighted for conductive carbon-black dispersion are CGPS 277A, CGPS 310W, and CGPS 700W, with CGPS 167W as a defoamer to help control processing foam. These BASF products provide solutions to deliver dispersion quality, viscosity control, and smoother handling of demanding conductive material formulations.

BASF technical experts are focused on addressing these market needs, and research is continuously expanding to identify the right additive solutions that enhance conductivity performance in batteries. BASF’s battery-additives address key industry challenges, including high slurry viscosity, dispersion of carbon nanotubes (CNT) and conductive carbon black, post-thickening, cracking, white spots, PVDF and Al2O3 particle dispersion, and substrate wetting, composed of high-end dispersants, wetting agents, and related additives as problem solvers for these application areas.

Where BASF Additives Can Help

BASF’s battery-additives story is therefore not just about entering a new market—it is about helping customers build better slurries, better coatings, and ultimately better manufacturing outcomes. As battery production scales and formulations become more demanding, dispersants, wetting agents, and foam-control additives will play an even more important role in enabling robust cathode, anode, and separator processing.

The message for the market is clear: optimizing battery manufacturing starts with well-designed slurry systems. BASF’s additive solutions are positioned to address the most critical formulation variables across cathode, anode, and separator applications- dispersion quality, wetting, viscosity control, defect reduction, and process robustness. As battery production scales and formulations become increasingly complex, the ability to maintain stable dispersion, control foam, and manage viscosity simultaneously will be essential for consistent and scalable manufacturing performance.