Mechanical structuring of graphite anodes substantially improves the electrochemical performance of lithium-ion batteries by facilitating lithium-ion diffusion through the electrode coatings. However, mechanical structuring using embossing rollers is not yet established in industrial battery production. During operation, residual active material accumulates on the roller surface, leading to surface contamination and inhomogeneous electrode compaction. Laser-based cleaning represents a promising approach for removing these residues inline and contact free while preserving the surface structures of the embossing rollers.

To establish a physical understanding of the laser cleaning process prior to its application on embossing rollers, this study investigates the laser-based removal of a graphite-based active material from metallic planar substrates and from structured planar substrates that represent simplified model surfaces of embossing rollers. A systematic experimental study using nanosecond pulsed laser radiation was conducted to investigate the influence of key processing parameters, including pulse duration, fluence, scanning speed, and pulse and line overlap, on graphite residue removal and the resulting surface morphology.

The processed surfaces were characterized by using optical microscopy and laser scanning microscopy to evaluate the ablation behavior and surface topography. The results demonstrate that graphite residues can be selectively removed within a defined parameter range while maintaining the integrity of the metallic substrate. The identified process window provides a physical basis for transferring laser-based cleaning strategies to structured embossing rollers in lithium-ion battery manufacturing.