Electric vehicle (EV) market has had an aggressive development in the last years, and Chinese market has more than 50% share of global capacity. However, there are still some important social barriers that must be overcome to get the expected BEV market penetration, mostly related to the cost, distance range capacity, charging time and infrastructure. Range anxiety is a key reason that consumers are reluctant to embrace EVs. To be truly competitive with gasoline vehicles, EVs should allow drivers to recharge quickly anywhere in any weather, like refueling gasoline cars, or carry more useful energies with high energy density lithium-ion batteries (LIBs). The need to improve performances and reduce costs of LIBs encourages different research strategies. In general, the methods toward achieving higher energy density LIBs can be summarized in two ways: ① the development of novel battery chemistries with higher specific capacity and ② the exploration of advanced battery configurations with increased electrochemical active material ratio via electrode architecture engineering. However, the novel battery chemistries have a long journey to be used industrially, structural engineering provides a feasible and universal way to further improve the energy density of LIBs without changing the fundamental battery chemistries. Recently the attention is focusing on increasing the electrodes areal capacity to enable the substantial reduction of the current collectors, porous separator, and electrolyte resulting in large gravimetric and volumetric energy density improvements as well as cost savings. Moreover, increasing electrode thickness and density is a most effective approach to achieve high energy density of LIBs, but high tortuosity and low wettability in the electrodes deteriorate the LIB performance, such power density and cycling life. Herein, we introduce various methods to create low tortuosity nanostructures, such as templating and micro fabrications, and the structural designs by adopting laser-structured or multi-layer coating technologies to realize a low tortuosity electrode in the commercialized LIBs are highlighted.