3D Printed Nitrogen-Doped Thick Carbon Architectures for Supercapacitor: Ink Rheology and Electrochemical Performance

Three-dimensional high-aspect-ratio microarray thick electrodes for high-rate hybrid supercapacitors

Hybrid supercapacitors (HSCs) with facile integration and high process compatibility are considered ideal power sources for portable consumer electronics. However, as a crucial component for storing energy, traditional thin-film electrodes exhibit low energy density. Although increasing the thickness of thin films can enhance the energy density of the electrodes, it gives rise to issues such as poor mechanical stability and long electron/ion transport pathways. Constructing a stable three-dimensional (3D) ordered thick electrode is considered the key to addressing the aforementioned contradictions. In this work, a manufacturing process combining lithography and chemical deposition techniques is developed to produce large-area and high-aspect-ratio 3D nickel ordered cylindrical array (NiOCA) current collectors. Positive electrodes loaded with nickel-cobalt bimetallic hydroxide (NiOCA/NiCo-LDH) are constructed by electrodeposition, and HSCs are assembled with NiOCA/nitrogen-doped porous carbon (NiOCA/NPC) as negative electrodes. The HSCs exhibits 55% capacity retention with the current density ranging from 2 to 50 mA cm-2. Moreover, it maintains 98.2% of the initial capacity after long-term cycling of 15,000 cycles at a current density of 10 mA cm-2. The manufacturing process demonstrates customizability and favorable repeatability. It is anticipated to provide innovative concepts for the large-scale production of 3D microarray thick electrodes for high-performance energy storage system.

Programmable and flexible wood-based origami electronics

Natural polymer substrates are gaining attention as substitutes for plastic substrates in electronics, aiming to combine high performance, intricate shape deformation, and environmental sustainability. Herein, natural wood veneer is converted into a transparent wood film (TWF) substrate. The combination of 3D printing and origami technique is established to create programmable wood-based origami electronics, which exhibit superior flexibility with high tensile strength (393 MPa) due to the highly aligned cellulose fibers and the formation of numerous intermolecular hydrogen bonds between them. Moreover, the flexible TWF electronics exhibit editable multiplexed configurations and maintain stable conductivity. This is attributed to the strong adhesion between the cellulose-based ink and TWF substrate by non-covalent bonds. Benefiting from its anisotropic structure, the programmability of TWF electronics is achieved through sequentially folding into predesigned shapes. This design not only promotes environmental sustainability but also introduces its customizable shapes with potential applications in sensors, microfluidics, and wearable electronics.

Opportunities at the Intersection of 3D Printed Polymers and Pyrolysis for the Microfabrication of Carbon-Based Energy Materials

In an era marked by a growing demand for sustainable and high-performance materials, the convergence of additive manufacturing (AM), also known as 3D printing, and the thermal treatment, or pyrolysis, of polymers to form high surface area hierarchically structured carbon materials stands poised to catalyze transformative advancements across a spectrum of electrification and energy storage applications. Designing 3D printed polymers using low-cost resins specifically for conversion to high performance carbon structures via post-printing thermal treatments overcomes the challenges of 3D printing pure carbon directly due to the inability of pure carbon to be polymerized, melted, or sintered under ambient conditions. In this perspective, we outline the current state of AM methods that have been used in combination with pyrolysis to generate 3D carbon structures and highlight promising systems to explore further. As part of this endeavor, we discuss the effects of 3D printed polymer chemistry composition, additives, and pyrolysis conditions on resulting 3D pyrolytic carbon properties. Furthermore, we demonstrate the viability of combining continuous liquid interface production (CLIP) vat photopolymerization with pyrolysis as a promising avenue for producing 3D pyrolytic carbon lattice structures with 15 μm feature resolution, paving way for 3D carbon-based sustainable energy applications.

Direct ink writing 3D printing of low-dimensional nanomaterials for micro-supercapacitors

Micro-supercapacitors (MSCs) have attracted significant attention for potential applications in miniaturized electronics due to their high power density, rapid charge/discharge rates, and extended lifespan. Despite the unique properties of low-dimensional nanomaterials, which hold tremendous potential for revolutionary applications, effectively integrating these attributes into MSCs presents several challenges. 3D printing is rapidly emerging as a key player in the fabrication of advanced energy storage devices. Its ability to design, prototype, and produce functional devices incorporating low-dimensional nanomaterials positions it as an influential technology. In this review, we delve into recent advancements and innovations in micro-supercapacitor manufacturing, with a specific focus on the incorporation of low-dimensional nanomaterials using direct ink writing (DIW) 3D printing techniques. We highlight the distinct advantages offered by low-dimensional nanomaterials, from quantum effects in 0D nanoparticles that result in high capacitance values to rapid electron and ion transport in 1D nanowires, as well as the extensive surface area and mechanical flexibility of 2D nanosheets. Additionally, we address the challenges encountered during the fabrication process, such as material viscosity, printing resolution, and seamless integration of active materials with current collectors. This review highlights the remarkable progress in the energy storage sector, demonstrating how the synergistic use of low-dimensional nanomaterials and 3D printing technologies not only overcomes existing limitations but also opens new avenues for the development and production of advanced micro-supercapacitors. The convergence of low-dimensional nanomaterials and DIW 3D printing heralds the advent of the next generation of energy storage devices, making a significant contribution to the field and laying the groundwork for future innovations.

Robust Graphene-based Aerogel for Integrated 3D Asymmetric Supercapacitors with High Energy Density

Three-dimensional asymmetric supercapacitors (3D ASC) have garnered significant attention due to their high operating window, theoretical energy density, and circularity. However, the practical application of 3D electrode materials is limited by brittleness and excessive dead volume. Therefore, we propose a controlled contraction strategy that regulates the pore structure of 3D electrode materials, eliminates dead volume in the 3D skeleton structure, and enhances mechanical strength. In this study to obtain reduced graphene oxide/manganese dioxide (rGO/MnO2) and reduced graphene oxide/carbon nanotube (rGO/CNT) composite aerogels with a stable and compact structure. MnO2 and CNT as nanogaskets, preventing the self-stacking of graphene nanosheets during the shrinkage process. Additionally, the high specific capacitor nanogaskets significantly enhance the specific energy density of the rGO aerogel electrode. The prepared rGO/MnO2//rGO/CNT 3D ASC exhibits a high mass-specific capacitance of 216.15 F g-1, a high mass energy density of 74 Wh kg-1 at 3.5 A g-1, and maintains a retention rate of capacitance at 99.89 % after undergoing 10,000 cycles of charge and discharge at 5 A g-1. The versatile and integrated assembly of 3D ASC units is achieved through the utilization of the robust mechanical structure of rGO-based aerogel electrodes, employing a mortise and tenon structural design.

Electrochemically Exfoliated Graphene Additive-Free Inks for 3D Printing Customizable Monolithic Integrated Micro-Supercapacitors on a Large Scale

Three-dimensional (3D) printing technology with enhanced fidelity can achieve multiple functionalities and boost electrochemical performance of customizable planar micro-supercapacitors (MSCs), however, precise structural control of additive-free graphene-based macro-assembly electrode for monolithic integrated MSCs (MIMSCs) remains challenging. Here, the large-scale 3D printing fabrication of customizable planar MIMSCs is reported utilizing additive-free, high-quality electrochemically exfoliated graphene inks, which is not required the conventional cryogenic assistance during the printing process and any post-processing reduction. The resulting MSCs reveal an extremely small engineering footprint of 0.025 cm2, exceptionally high areal capacitance of 4900 mF cm-2, volumetric capacitance of 195.6 F cm-3, areal energy density of 2.1 mWh cm-2, and unprecedented volumetric energy density of 23 mWh cm-3 for a single cell, surpassing most previously reported 3D printed MSCs. The 3D printed MIMSC pack is further demonstrated, with the maximum areal cell count density of 16 cell cm-2, the highest output voltage of 192.5 V and the largest output voltage per unit area of 56 V cm-2 up to date are achieved. This work presents an innovative solution for processing high-performance additive-free graphene ink and realizing the large-scale production of 3D printed MIMSCs for planar energy storage.

Direct Ink Writing 3D Printing for High-Performance Electrochemical Energy Storage Devices: A Minireview

Despite tremendous efforts that have been dedicated to high-performance electrochemical energy storage devices (EESDs), traditional electrode fabrication processes still face the daunting challenge of limited energy/power density or compromised mechanical compliance. 3D thick electrodes can maximize the utilization of z-axis space to enhance the energy density of EESDs but still suffer from limitations in terms of poor mechanical stability and sluggish electron/ion transport. Direct ink writing (DIW), an eminent branch of 3D printing technology, has gained popularity in the manufacture of 3D electrodes with intricately designed architectures and rationally regulated porosity, promoting a triple boost in areal mass loading, ion diffusion kinetics, and mechanical flexibility. This focus review highlights the fundamentals of printable inks and typical configurations of 3D-printed devices. In particular, preparation strategies for high-performance and multifunctional 3D-printed EESDs are systemically discussed and classified according to performance evaluation metrics such as high areal energy density, high power density, high volumetric energy density, and mechanical flexibility. Challenges and prospects for the fabrication of high-performance 3D-printed EESDs are outlined, aiming to provide valuable insights into this thriving field.

Engineering Interfacial Built-in Electric Field in Polymetallic Phosphide Heterostructures for Superior Supercapacitors and Electrocatalytic Hydrogen Evolution

Herein, a patterned rod-like CoP@NiCoP core-shell heterostructure is designed to consist of CoP nanowires cross-linked with NiCoP nanosheets in tight strings. The interfacial interaction within the heterojunction between the two components generates a built-in electric field that adjusts the interfacial charge state and create more active sites, accelerating the charge transfer and improving supercapacitor and electrocatalytic performance. The unique core-shell structure suppresses the volume expansion during charging and discharging, achieving excellent stability. As a result, CoP@NiCoP exhibits a high specific capacitance of 2.9 F cm-2 at a current density of 3 mA cm-2 and a high ion diffusion rate (Dion is 2.95 × 10-14  cm2  s-1 ) during charging/discharging. The assembled asymmetric supercapacitor CoP@NiCoP//AC exhibits a high energy density of 42.2 Wh kg-1 at a power density of 126.5 W kg-1 and excellent stability with a capacitance retention rate of 83.8% after 10 000 cycles. Furthermore, the modulated effect induced by the interfacial interaction also endows the self-supported electrode with excellent electrocatalytic HER performance with an overpotential of 71 mV at 10 mA cm-2 . This research may provide a new perspective on the generation of built-in electric field through the rational design of heterogeneous structures for improving the electrochemical and electrocatalytical performance.

Ultrafine Electrospun Cobalt-Molybdenum Bimetallic Nitride as a Durable Electrocatalyst for Hydrogen Evolution

Transition metal nitrides are promising electrocatalysts for hydrogen evolution reaction (HER) owing to their Pt-like electronic structure. However, the harsh nitriding conditions greatly limit their large-scale applications. Herein, ultrafine Co₃Mo₃N-Mo₂C (<1 nm)-decorated carbon nanofibers (Co₃Mo₃N-Mo₂C/CNFs) were prepared by electrostatic spinning followed by pyrolysis treatment, in which the MoCo-MOF simultaneously serves as the precursor and nitrogen source. The generated synergistic interactions between Mo₂C and Co₃Mo₃N significantly adjust the electronic structure of Mo₂C and afford a fast charge transfer, which endows the resultant hybrid with superior HER electrocatalytic performances. Specifically, the as-obtained Co₃Mo₃N-Mo₂C/CNF delivers a low overpotential of only 76 mV to achieve a current density of 10 mA cm^-2 and superior durability with no obvious degradation for 200 h in acidic media. This performance outperforms most of the transition metal-based electrocatalysts reported to date. This work paves a new way for the design of catalysts with ultrasmall size and high efficiency in energy conversion.