A possible way to increase the energy density in lithium-ion batteries, and, at the same time, reduce the production costs, is to use thicker electrodes. However, transport limitations can occur in thick electrodes, leading to a drawback in performance. A way to mitigate this problem is a more sophisticated microstructure of the electrode, using, e.g., structural gradients. This can, for instance, be achieved by multi-layer casting, i.e., casting and drying of a first layer, and then adding a second layer. An important question is how the interface between the two layers is shaped and how the corresponding microstructure influences the electrochemical performance. In the present paper, two different two-layer cathodes are analyzed and compared to single-layer cathodes of the same thickness. The analysis involved tomographic imaging, a statistical analysis of the 3D microstructure of the active material particle systems with a focus on the interface between the layers, and electrochemical characterization of the active material systems using experimental measurements as well as electrochemical simulations. The analysis showed that at the interface the connectivity of active material particles decreases, which results in higher electric resistivity. This effect is stronger if an intermediate calendering step is performed, i.e., the first layer is calendered before casting the second layer
