Practical Lithium–Sulfur Batteries: An Integrated Design Roadmap from High‐Loading Cathodes to High‐Energy Pouch Cells

ABSTRACT The transition to a sustainable energy future requires electrochemical storage systems that surpass conventional lithium‐ion batteries. The lithium–sulfur (Li–S) battery, with its high theoretical energy density and use of abundant sulfur, is a paramount contender for next‐generation applications. However, its commercialization is hindered by intrinsic challenges: the insulating nature of sulfur, the deleterious polysulfide shuttle effect, and severe volumetric expansion. For over a decade, research has focused on nanomaterial engineering under idealized laboratory conditions, yielding metrics often divorced from practical reality. This review argues that overcoming these barriers necessitates a decisive paradigm shift from isolated material breakthroughs to the synergistic integration of three interdependent frontiers. First, the scale‐up imperative, translating nanoscale innovations into manufacturable, high‐loading electrodes validated in lean‐electrolyte pouch cells (where the electrolyte‐to‐sulfur ratio, E/S is minimized). Second, electrolyte‐cathode synergy, co‐engineering an integrated system where components are mutually reinforcing. Third, systematic, data‐driven optimization using advanced operando characterization, multi‐physics modeling, and artificial intelligence (AI) to navigate the complex parameter space. By deconstructing these gaps, we synthesize a pragmatic roadmap emphasizing integration and practical validation. We posit that only through coordinated advances across these interconnected domains can the transformative potential of high‐energy‐density lithium–sulfur batteries be fully realized for applications like electric aviation and grid storage.