Sodium-ion batteries are gaining increasing attention as a promising technology for cost-effective large-scale energy storage applications such as grid stabilization, backup power, and stationary energy systems. Among potential cathode materials, iron- and manganese-based Prussian Blue Analog (PBA) compounds are particularly attractive due to their cobalt- and nickel-free composition, abundance of raw materials, and favorable electrochemical properties. This work focuses on manufacturing-relevant electrode development using a water-based processing route as a sustainable alternative to the conventional N‑methyl‑2‑pyrrolidone (NMP)-based fabrication method. The aqueous processing approach was systematically evaluated with respect to slurry preparation, drying behavior, moisture sensitivity, and electrode handling.

To assess performance under realistic conditions, electrolyte screening and electrochemical testing were performed directly in pouch cell configurations, including high-rate cycling and power capability measurements. The water-processed Fe/Mn-PBA electrodes demonstrate stable electrochemical performance and competitive cycling stability when process parameters are carefully controlled. These results provide valuable insights into slurry formulation, electrode integrity, and electrolyte compatibility—factors that are often underestimated during laboratory-scale development but are essential for scalable manufacturing. Overall, this study highlights the potential of water-based processing as a viable and sustainable pathway toward industrially relevant sodium-ion battery production for advanced energy storage applications.