A Guide from Laboratory Jet Milling as an Enabling Step in Sustainable All-Dry Manufacturing of Battery Materials

Abstract

Lithium-ion battery (LIB) cathodes such as LiNi_xMn_yCo_1-x-yO₂ (NMC) and LiFePO₄ (LFP) dominate the market, yet conventional synthesis relies on water and energy intensive aqueous processes. All-dry manufacturing eliminates these issues, with jet milling (fluid-energy milling) enabling effective deagglomeration of sintered single-crystal NMC particles into discrete ~3 μm primaries with minimal contamination or damage. This study provides a detailed guide to laboratory-scale jet milling, covering equipment design, basic principles, and operation protocols (with supplementary instructional video). Using all-dry synthesized LiNi_0.5Mn_0.3Co_0.2O₂ (NMC532) as a case study, we demonstrate that optimal grinding pressure (120 psi) and feed rate (0.1–1.5 g min^-1) produce uniform, and narrow particle size distributions even after reheating step. We also provide an outlook on additional potential applications of jet milling in battery material processing. These advancements support the sustainable energy transition amid surging global battery demand.