(Battery Division Postdoctoral Associate Research Award Sponsored by MTI Corporation and the Jiang Family Foundation) 3D Printing of Batteries: Fiction or Reality?

Motivated by the request to build shape-conformable flexible, wearable and customizable batteries while maximizing the energy storage and electrochemical performances, additive manufacturing (AM) appears as a revolutionary discipline. Battery components such as electrodes, separator, electrolyte, current collectors and casing can be tailored with any shape, allowing the direct incorporation of batteries and all electronics within the final three-dimensional object. AM also paves the way toward the implementation of complex 3D electrode architectures that could enhance significantly the power battery performances. Transitioning from conventional 2D to complex 3D lithium-ion battery (LIB) architectures will increase the electrochemically active surface area, enhance the Li+ diffusion paths, thus leading to improved specific capacity and power performance [1]. Our recent modeling studies [2] involving the simulation of a classical Ragone plot illustrated that a gyroid 3D battery architecture has +158% performance at a high current density of 6C, in comparison to planar geometry. In this presentation, an overview of current trends in energy storage 3D printing will be discussed [3-11]. A summary of our recent works on lithium-ion battery 3D printing via Thermoplastic Material Extrusion / Fused Deposition Modeling will be presented [12-16]. The development of printable composite filaments (Graphite-, LiFePO4-, Li2TP-, PEO/LiTFSI-, SiO2-, Ag/Cu-based) corresponding to each part of a LIB (electrodes, electrolyte, separator, current collectors), and the importance of introducing a plasticizer (polyethylene glycol dimethyl ether average Mn 500 for polylactic acid) as an additive to enhance the printability will be addressed. Printing of the complete LIB in a single step using multi-material printing options, and the implementation of a solvent-free protocol [14] will also be discussed. Second part of this presentation will be dedicated to AM of batteries by means of Vat Photopolymerization (VPP) processes, including stereolithography, digital light processing and two-photon polymerization (offering a greater resolution down to 0.1μm), to print high resolution battery components [10]. Composite resins formulation approaches based on the introduction of solid battery particles or precursor salts will be introduced [17, 18]. Finally, an overview of our ongoing project dedicated to AM of sodium-ion batteries from resources available on the Moon and Mars will be present