Due to their high theoretical energy density, all solid state lithium sulfur batteries (ASSBLSB) represent one of the most promising candidates for next-generation energy storage systems. Whilst high sulfur utilizations have been published for several cathode compositions and preparation methods in recent years, there is still a lack of clarity regarding the influence of the used carbon. Furthermore, ASSBLSBs face challenges in up-scaling as the common preparation methods including high energy ball milling are time consuming, batch-wise and need high energy impact. Additionally, investigations under realistic conditions on pouch cell level are challenging, as it is necessary to implement a scalable preparation method for sheet-type cathodes with high sulfur utilization and loading.

In this study, we demonstrate the manual production of solvent-free cathodes, as well as the production via the scalable DRYtraec® process, where double coated cathode sheets are obtained. Manually produced sheet-type cathodes, prepared via high energy ball milling, reached nearly theoretical sulfur utilization of 1672 mAh g 1 and outstanding reversible capacity retention with 84 % of initial discharge capacity after 300 cycles. Additionally, the influence of carbon porosity on the electrochemical performance using low energy ball milling is discussed, in order to enable up-scalable processing techniques with reduced energy impact. Furthermore, we demonstrate an all-solid-state pouch cell using the dry film cathode, which is successfully tested for 50 cycles at different C-rates. Thickness monitoring of the cell stack gives fundamental insights into the volume change and breathing behavior of both, cathode and anode.