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.
Opening soon
Bring one slurry question.
Fixed-scope reviews are being prepared. Join the launch list to hear first when bookings open.
Who is behind it
Twenty years in ceramic and chemical materials processing.
Professional Engineer (Ceramics) · International Professional Engineer (Chemical Engineering) · APEC Engineer. A production engineer specialising in scale-up, with multiple patents and technology transfers in chemical and materials processing.
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.