01 · ENERGY
Battery electrode slurries
- Active material and conductive-additive dispersion
- Solids loading vs coatability
- Coating weight variation and drying defects
Slurry and 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 and porous materials.
01
Formulate
Powder, binder, solvent, additives.
02
Measure
Flow curves, yield stress, stability.
03 · core
Predict and diagnose
Read the gap between model and measurement.
04
Form and 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 and coatings
- Tape and slip casting slurries
- Coating thickness variation, wetting and surfactants
- Green-body cracking and shrinkage
03 · POROUS MATERIALS
MOF and 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 and 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 and diagnosis
Viscosity predicted from formulation data, compared with measurement — the residual points to the likely cause.
04 / FORMING
Forming and 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.
- 01 · INPUTFormulation dataSolids loading, particle size, binder and dispersant.→
- 02 · MODELPredicted curveThe viscosity the formulation alone should give.↓
- 03 · YOUR DATAMeasured curveYour rheometer flow curve for the same slurry.→
- 04 · RESULTResidual → likely causeDispersion, raw material or measurement — and the next test.
Insights
Production technology, read for process.
A weekly watch on production technology across batteries, semiconductors, ceramics, catalysts, MOFs, chemicals and advanced materials, plus process-focused reviews of research and patents.
Services · opening soon
Fixed-scope reviews for one clear question.
01 · FOCUSED
Quick Check
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
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
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 fixed day rate
Each service has a fixed scope and a fixed price. Bookings open soon. See pricing → · 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.