As electric vehicles (EVs) have replaced internal combustion engine vehicles (ICEVs), there's a requirement to increase the energy density of lithium-ion batteries (LIBs) to match the mileage capabilities of ICEVs. Achieving this accompanies optimization in the calendering process, which plays a crucial role in designing high-energy-density LIBs under the same materials. A well-designed calendering process not only boosts energy density but also improves the electronic conductivity and mechanical durability of electrodes. However, excessive calendering can result in detrimental effects such as the formation of tortuous ion percolation pathways and mechanical breakdown like crack formation in active materials. This underscores the importance of understanding how calendering impacts the microstructure of composite electrodes, which varies depending on the pressure levels applied. Therefore, a thorough analysis of the effect of the calendering process on composite electrodes is essential. Nonetheless, it is challenging to analyze microstructural changes and correlate them with electrochemical characteristics solely through experimental means.Addressing this challenge, herein, digital twin 3D structures of composite electrodes were obtained from FIB-SEM tomographic images before and after the calendering process. Subsequently, simulations of the calendering process are conducted to analyze the microstructure evolution depending on the calendering ratio or electrode density. As a result, virtual structures derived from the calendering simulation are created with varying densities. Key parameters related to electrochemical performance are calculated, enabling a systematic analysis of the structural, electrochemical, and mechanical characteristics during the calendering process.
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