In conventional lithium-ion battery (LIB) manufacturing, N-methyl-2-pyrrolidone (NMP) is commonly used as a solvent 

for slurry-based cathode fabrication, despite its high cost and environmental burden. To overcome these limitations, 

NMP-free electrode fabrication strategies have been proposed as practical alternatives. In this study, NMP-free electrodes 

were fabricated using three different mixing methods and two binder systems, including powder-based processing and a 

solvent-assisted PTFE fibrillation approach employing low-toxicity volatile solvents. The electrochemical performance of 

the electrodes was evaluated through galvanostatic charge–discharge testing and differential capacity (dQ/dV) analysis. 

The solvent-assisted PTFE-based electrode exhibited reduced surface roughness, low irreversible capacity, and stable 

cycling behavior, whereas powder-based electrodes showed increased irreversible capacity and accelerated degradation. 

Differential capacity analysis revealed that in NMP-free electrode systems, the electrode morphology is governed by the 

combined effects of mixing strategy, binder system, and fabrication process, which together influence interfacial stability 

and electrochemical behavior. These results demonstrated that mixing strategy and binder behavior played critical roles 

in determining the performance of NMP-free electrodes, providing practical insights for cost-effective and high-arealcapacity

LIB fabrication.