01 · ENERGY
Battery electrode slurries
- Active material and conductive-additive dispersion
- Solids loading vs coatability
- Coating weight variation and drying defects
Slurry & powder process engineering
Know how your slurry will behave — before it reaches the line.
Rheology-based engineering for formulation, coating, forming and scale-up — applied to battery electrodes, ceramics and coatings, and MOF & porous materials.
01
Formulate
Powder, binder, solvent, additives.
02
Measure
Flow curves, yield stress, stability.
03 · core
Predict & diagnose
Read the gap between model and measurement.
04
Form & scale
Coat, cast, extrude, granulate.
Why rheology
Most forming defects start in the slurry.
Uneven coatings, cracked green bodies and weak pellets are usually traced back to dispersion, solids loading and flow behaviour — long before drying or firing. Measuring and predicting that behaviour is the cheapest point to fix a process.
Applications
One discipline, three material fields.
02 · CERAMICS
Ceramics & coatings
- Tape and slip casting slurries
- Coating thickness variation, wetting and surfactants
- Green-body cracking and shrinkage
03 · POROUS MATERIALS
MOF & porous materials
- Paste formulation for extrusion and granulation
- Binders that keep surface area
- Monolith and substrate coating
Technology
From formulation to a process that scales.
01 / FORMULATION
Formulation & dispersion
Particle size, solids loading, binder and dispersant selection, mixing sequence.
02 / MEASUREMENT
Rheology measurement
Flow curves, yield stress, thixotropy and stability — chosen to match the process step.
03 / PREDICTION · CORE
Prediction & diagnosis
Viscosity predicted from formulation data, compared with measurement — the residual points to the likely cause.
04 / FORMING
Forming & scale-up
Coating, casting, extrusion and granulation windows; drying and quality checks.
How diagnosis works
The gap between prediction and measurement is the clue.
When a slurry behaves differently from what its formulation predicts, the difference is rarely random. Its size and pattern help separate dispersion problems, raw-material variation and measurement issues — so the next test is the right one.
Formulation data
Predicted curve
Measured curve
Residual → likely cause
Insights
Research, read for process.
01 · PAPER & PATENT REVIEWS
Published research and patents, read for what they reveal about the process.
Electrode slurry stability: what recent papers measure — and what they missComing soon
Reading a MOF shaping patent for process cluesComing soon
02 · TECHNOLOGY WATCH
Public milestones across our material fields, with links to the source.
MOF · continuous flowPromethean Particles reports tonne-scale flow synthesis ↗
03 · PROCESS GUIDES
Practical primers for formulation and forming.
Yield stress or viscosity: which number predicts coating defects?Coming soon
From powder to pellet: extrusion, granulation and coating basicsComing soon
Services & pricing · opening soon
Fixed-scope reviews. Clear prices.
01 · FOCUSED
Quick Check
$450 USD, fixed
A second opinion on one formulation before you commit to more tests.
- Review of one formulation and its flow-curve data
- 2–3 page memo: what the data shows and does not show
- Most likely causes and 1–3 next checks
- One round of written follow-up questions
02 · CORE SERVICE
Rheology Diagnostic Report
$1,950 USD, fixed
For recurring variation you need to explain — and a plan to fix it.
- Formulation-based viscosity prediction compared with your measurements
- Residual analysis separating dispersion, raw-material and measurement effects
- Ranked cause hypotheses with evidence for and against
- Prioritised test plan with measurement-protocol notes
- 30-minute video call to walk through the findings
03 · MULTI-STEP
Process Review
from $4,500 USD
Several formulations or process steps, from mixing to coating, forming and drying.
- Scope agreed after a short intro call
- Written report covering each agreed step
- Two review calls
- Agreed extensions at a day rate of $1,200
Planned launch pricing · USD · Bookings open soon — join the launch list to be notified first · See a sample report →
Who is behind it
Twenty years in ceramic and chemical materials processing.
Professional Engineer (Ceramics), Korea · IntPE (Chemical Engineering). Background in computational chemistry and slurry viscosity prediction.
About TheBulkLab →How we work
Evidence first. No unsupported promises.
Observations are kept separate from hypotheses, the limits of the available data are stated, and every recommendation is a test for your team to validate before production.