Si anodes suffer
from poor cycling efficiency because of the pulverization
induced by volume expansion, lithium trapping in Li–Si alloys,
and unfavorable interfacial side reactions with the electrolyte; the
comprehensive consideration of the Si anode design is required for
their practical deployment. In this article, we develop a cabbage-inspired
graphite scaffold to accommodate the volume expansion of silicon particles
in interplanar spacing. With further interfacial modification and
prelithiation processing, the Si@G/C anode with an areal capacity
of 4.4 mA h cm–2 delivers highly reversible cycling
at 0.5 C (Coulombic efficiency of 99.9%) and a mitigated volume expansion
of 23%. Furthermore, we scale up the synthetic strategy by producing
10 kg of the Si@G/C composite in the pilot line and pair this anode
with a LiNi0.8Co0.1Mn0.1O2 cathode in a 1 A h pouch-type cell. The full-cell prototype realizes
a robust cyclability over 500 cycles (88% capacity retention) and
an energy density of 301.3 W h kg–1 at 0.5 C. Considering
the scalable fabrication protocol, holistic electrode formulation
design, and harmony integration of key metrics evaluated both in half-cell
and full-cell tests, the reversible cycling of the prelithiated silicon
species in the graphite scaffold of the composite could enable feasible
use of the composite anode in high-energy density lithium batteries.