The charged particles migrate to a deposition substrate, then are deposited onto it and form a layer by deposits build-up. In its simplest form, EPD exploits the direct interaction of charged particles in a colloidal electrolyte with an electric field. Although our understanding of the deposition mechanisms and fundamental manufacturing aspects is still far from complete, this has clearly not prevented the use of this highly versatile technology on an industrial scale. It continues to offer a wealth of possibilities to deposit coatings with controllable features (thin or thick layers, 2D or 3D shapes, compact or porous, composite or graded or multi-layered). The high level of automation, low levels of pollution and homogeneity of deposited layers are advantages that led to the successful application of this technique for coating paints onto car bodies. Introduction Electrophoretic deposition (EPD) has been employed in the electrophoretic paints industry since the 1970s. In short, this research shows the successful production of practical EPD electrodes for electrochemical energy storage, which is directly relevant for scale-up industrial adoption and can be applied as a platform electrode manufacturing technology for any battery and supercapacitor materials. Electrochemical performance of EPD over slurry casting is presented.

Prototype A7 sized pouch cells were assembled and tested to show evidence of practical EPD electrodes in a commercial cell format. Materials and electrode properties were studied by various charactersisation tools. Research investigations including colloidal electrolyte formulations, electrode deposition parameters and cell performance testing are reported. Practical electrodes with commercially viable parameters are shown, specifically high density active material (in excess of 9.8 mg cm −2) and very thick coating layer (about 168 μm). Using activated carbon (AC) as an exemplary supercapacitor material, this study reports the practical aspects of porous energy storage electrodes produced by the EPD technique. Recent years are seeing increasing evidence in using this technique to produce energy storage electrodes (notably for lithium-ion batteries, solid-state devices, supercapacitors, and flow batteries), but their advancement for industrialisation remains unclear. Electrophoretic deposition (EPD) is a highly convenient and demonstrated industrial operation for the manufacture of surface coatings.

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