Recent advances and perspectives of 3D printed micro-supercapacitors: from design to smart integrated devices

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.

Ink-based additive manufacturing for electrochemical applications

Additive manufacturing (AM), commonly known as three-dimensional (3D) printing, has drawn substantial attention in recent decades due to its efficiency and precise control in part fabrication. The limitations of conventional fabrication processes, especially regarding geometry complexity, supply chain, and environmental impact, have prompted the exploration of diverse AM technologies in electrochemistry. Especially, three ink-based AM techniques, binder jet printing (BJP), direct ink writing (DIW), and Inkjet Printing (IJP), have been extensively applied by numerous research teams to produce electrodes, catalyst scaffolds, supercapacitors, batteries, etc. BJP's versatility in utilizing a wide range of materials as powder feedstock promotes its potential for various electrode and battery applications. DIW and IJP stand out for their ability to handle multi-material manufacturing tasks and deliver high printing resolution. To capture recent advancements in this field, we present a comprehensive review of the applications of BJP, DIW, and IJP techniques in fabricating electrochemical devices and components. This review intends to provide an overview of the process-structure-property relationship in electrochemical materials and components across diverse applications manufactured using AM techniques. We delve into how the significantly improved design freedom over the structure offered by these ink-based AM techniques highlights the performance of electrochemical products. Moreover, we highlight their advantages in terms of material compatibility, geometry control, and cost-effectiveness. In specific cases, we also compare the performance of electrochemical components fabricated using AM and conventional manufacturing methods. Finally, we conclude this review article by offering some insights into the future development in this research field.

Gallium-Carbon: A Universal Composite for Sustainable 3D Printing of Integrated Sensor-Heater-Battery Systems in Wearable and Recyclable Electronics

This study presents a novel three-dimensional (3D) printable gallium-carbon black-styrene isoprene styrene block copolymer (Ga-CB-SIS), offering a versatile solution for the rapid fabrication of stretchable and integrated sensor-heater-battery systems in wearable and recyclable electronics. The composite exhibits sinter-free characteristics, allowing for printing on various substrates, including heat-sensitive materials. Unlike traditional conductive inks, the Ga-CB-SIS composite, composed of gallium, carbon black, and styrene isoprene block copolymers, combines electrical conductivity, stretchability, and digital printability. By introducing carbon black as a filler material, the composite achieves promising electromechanical behavior, making it suitable for low-resistance heaters, batteries, and electrical interconnects. The fabrication process involves a simultaneous mixing and ball-milling technique, resulting in a homogeneous composition with a CB/Ga ratio of 4.3%. The Ga-CB-SIS composite showcases remarkable adaptability for digital printing on various substrates. Its self-healing property and efficient recycling technique using a deep eutectic solvent contribute to an environmentally conscious approach to electronic waste, with a high gallium recovery efficiency of ∼98%. The study's innovation extends to applications, presenting a fully digitally printed stretchable Ga-CB-SIS battery integrated with strain sensors and heaters, representing a significant leap in LM-based composites. This multifunctional and sustainable Ga-CB-SIS composite emerges as a key player in the future of wearable electronics, offering integrated circuits with sensing, heating, and energy storage elements.

Recent progress of high-performance in-plane zinc ion hybrid micro-supercapacitors: design, achievements, and challenges

With the increasing demand for wearable and miniature electronics, in-plane zinc (Zn) ion hybrid micro-supercapacitors (ZIHMSCs), as a promising and compatible energy power source, have attracted tremendous attention due to their unique merits. Despite enormous development and breakthroughs in this field, there is still a lack of a systematic and comprehensive review to update the recent progress of in-plane ZIHMSCs in the design and fabrication of both micro-anodes and micro-cathodes, the exploration and optimization of new electrolytes, and the investigation of related-energy storage mechanisms. This minireview summarizes the key breakthroughs and recent advances in the construction of high-performance in-plane ZIHMSCs. First, the background and fundamentals of in-plane ZIHMSCs are briefly introduced. Then, new concepts, strategies, and latest exciting developments in the preparation and interfacial engineering of Zn metal micro-anodes, the fabrication of advanced micro-cathodes, and the exploration of new electrolyte systems are discussed, respectively. Finally, the key challenges and future directions for the development of high-performance in-plane ZIHMSCs are presented as well. This review not only accounts for the recent research progress in the field of the in-plane ZIHMSCs, but also provides important new insights into the design of next-generation miniaturized energy storage devices.

Design of internally integrated in-plane electrodes for superior flexible hybrid zinc-ion capacitor devices

A unique configuration based on internally integrated electrodes is proposed for flexible hybrid zinc-ion capacitor (HZIC) devices. An in-depth charge storage process is studied, confirming the high electrochemical promise of HZICs for future practical applications.

Nano-Additive Manufacturing and Non-Destructive Testing of Nanocomposites

In the present work, the recent advancements in additive manufacturing (AM) techniques for fabricating nanocomposite parts with complex shaped structures are explained, along with defect non-destructive testing (NDT) methods. A brief overview of the AM processes for nanocomposites is presented, grouped by the type of feedstock used in each technology. This work also reviews the defects in nanocomposites that can affect the quality of the final product. Additionally, a detailed description of X-CT, ultrasonic phased array technology, and infrared thermography is provided, highlighting their potential application in non-destructive inspection of nanocomposites in the future. Lastly, it concludes by offering recommendations for the development of NDT methods specifically tailored for nanocomposites, emphasizing the need to utilize NDT methods for optimizing nano-additive manufacturing process parameters, developing new NDT techniques, and enhancing the resolution of existing NDT methods.

Fabrication of Fe-Fe1-xO based 3D coplanar microsupercapacitors by electric discharge rusting of pure iron substrates

Iron oxides with advanced functional properties show great potential for applications in the fields of water splitting, drug delivery, sensors, batteries and supercapacitors. However, it is challenging to develop a simple and efficient strategy for fabricating patterned iron oxide based electrodes for supercapacitor applications. Herein, a facile, simple, scalable, binder-free, surfactant-free and conductive additive-free electric discharge rusting (EDR) technique is proposed to directly synthesize Fe1-xO oxide layer on a pure iron substrate. This new EDR strategy is successfully adopted to fabricate Fe-Fe1-xO integrative patterned electrodes and coplanar microsupercapacitors (CMSC) in one step. The CMSC devices with different geometries could be directly patterned by EDR, which is automatically controlled by a computer numerical control system. The fabricated Fe-Fe1-xO based 3D 2F-CMSC exhibits a maximum areal specific capacitance of 112.4 mF cm-2. Another important finding is the fabrication of 3D 2F-CMSC devices, which show good capacitive behavior at an ultra high scanning rate of 20 000 mV s-1. The results prove that EDR is a low-cost and versatile strategy for the scalable fabrication of high-performance patterned supercapacitor integrative electrodes and devices. Furthermore, it is a versatile technique which shows a great potential for development of next generation microelectronic devices, such as microbatteries and microsensors.

Recent Progress in Printed Photonic Devices: A Brief Review of Materials, Devices, and Applications

Printing electronics incorporates several significant technologies, such as semiconductor devices produced by various printing techniques on flexible substrates. With the growing interest in printed electronic devices, new technologies have been developed to make novel devices with inexpensive and large-area printing techniques. This review article focuses on the most recent developments in printed photonic devices. Photonics and optoelectronic systems may now be built utilizing materials with specific optical properties and 3D designs achieved through additive printing. Optical and architected materials that can be printed in their entirety are among the most promising future research topics, as are platforms for multi-material processing and printing technologies that can print enormous volumes at a high resolution while also maintaining a high throughput. Significant advances in innovative printable materials create new opportunities for functional devices to act efficiently, such as wearable sensors, integrated optoelectronics, and consumer electronics. This article provides an overview of printable materials, printing methods, and the uses of printed electronic devices.

Ultrathin Li-rich Li-Cu alloy anode capped with lithiophilic LiC6 headspace enabling stable cyclic performance

Li-rich dual-phase Li-Cu alloy is a promising candidate toward practical application of Li metal anode due to its in situ formed unique three-dimensional (3D) skeleton of electrochemical inert LiCu_x solid-solution phase. Since a thin layer of metallic Li phase appears on the surface of as-prepared Li-Cu alloy, the LiCu_x framework cannot regulate Li deposition efficiently in the first Li plating process. Herein, a lithiophilic LiC₆ headspace is capped on the upper surface of the Li-Cu alloy, which can not only offer free space to accommodate Li deposition and maintain dimensional stability of the anode, but also provide abundant lithiophilic sites and guide Li deposition effectively. This unique bilayer architecture is fabricated via a facile thermal infiltration method, where the Li-Cu alloy layer with an ultrathin thickness around 40 μm occupies the bottom of a carbon paper (CP) sheet, and the upper part of this 3D porous framework is reserved as the headspace for Li storage. Notably, the molten Li can quickly convert these carbon fibers of the CP into lithiophilic LiC₆ fibers while the CP is touched with the liquid Li. The synergetic effect between the LiC₆ fibers framework and LiCu_x nanowires scaffold can ensure a uniform local electric field and stable Li metal deposition during cycling. As a consequence, the CP capped ultrathin Li-Cu alloy anode demonstrates excellent cycling stability and rate capability.

3D printing for personalised medicines: implications for policy and practice

The current healthcare dynamic has shifted from one-size-fits-all to patient-centred care, with our increased understanding of pharmacokinetics and pharmacogenomics demanding a switch to more individualised therapies. As the pharmaceutical industry remains yet to succumb to the push of a technological paradigm shift, pharmacists lack the means to provide completely personalised medicine (PM) to their patients in a safe, affordable, and widely accessible manner. As additive manufacturing technology has already established its strength in producing pharmaceutical formulations, it is necessary to next consider methods by which this technology can create PM accessible from pharmacies. In this article, we reviewed the limitations of current pharmaceutical manufacturing methods for PMs, three-dimensional (3D) printing techniques that are most beneficial for PMs, implications of bringing this technology into pharmacy practice, and implications for policy surrounding 3D printing techniques in the manufacturing of PMs.

Circular Economy Electrochemistry: Creating Additive Manufacturing Feedstocks for Caffeine Detection from Post-Industrial Coffee Pod Waste

The recycling of post-industrial waste poly(lactic acid) (PI-PLA) from coffee machine pods into electroanalytical sensors for the detection of caffeine in real tea and coffee samples is reported herein. The PI-PLA is transformed into both nonconductive and conductive filaments to produce full electroanalytical cells, including additively manufactured electrodes (AMEs). The electroanalytical cell was designed utilizing separate prints for the cell body and electrodes to increase the recyclability of the system. The cell body made from nonconductive filament was able to be recycled three times before the feedstock-induced print failure. Three bespoke formulations of conductive filament were produced, with the PI-PLA (61.62 wt %), carbon black (CB, 29.60 wt %), and poly(ethylene succinate) (PES, 8.78 wt %) chosen as the most suitable for use due to its equivalent electrochemical performance, lower material cost, and improved thermal stability compared to the filaments with higher PES loading and ability to be printable. It was shown that this system could detect caffeine with a sensitivity of 0.055 ± 0.001 μA μM^-1, a limit of detection of 0.23 μM, a limit of quantification of 0.76 μM, and a relative standard deviation of 3.14% after activation. Interestingly, the nonactivated 8.78% PES electrodes produced significantly better results in this regard than the activated commercial filament toward the detection of caffeine. The activated 8.78% PES electrode was shown to be able to detect the caffeine content in real and spiked Earl Grey tea and Arabica coffee samples with excellent recoveries (96.7-102%). This work reports a paradigm shift in the way AM, electrochemical research, and sustainability can synergize and feed into part of a circular economy, akin to a circular economy electrochemistry.

Inkjet Printing of MnO2 Nanoflowers on Surface-Modified A4 Paper for Flexible All-Solid-State Microsupercapacitors

Printing technologies are gaining growing attention as a sustainable route for the fabrication of high-performance and flexible power sources such as microsupercapacitors (MSCs). Here, the inkjet printing method is utilized for the fabrication of manganese dioxide (MnO₂)-based, flexible all-solid-state MSCs on surface-modified A4 paper substrate. The appropriate rheology of the formulated ethanol-based ink (Fromm number <10) and the proper dimensions of MnO₂ nanoflowers (average size ∼600 nm) ensure a reliable inkjet printing process. Moreover, the underlying graphene/Ag nanowire pattern serves as a primer and highly conductive (R_s < 2 Ω sq^-1) layer on top of the paper to facilitate the anchoring of MnO₂ nanoflowers and rapid electron transportation. The resulting all-solid-state MSCs deliver a maximum areal capacitance of 0.68 mF cm^-2 at a current density of 25 μA cm^-2, reasonable durability (>80% of capacity remained after 3000 cycles), and remarkable foldability. Additionally, the inkjet-printed MSC devices deliver a superior areal energy density of 0.01 μWh cm^-2 and also a power density of 1.19 μW cm^-2. This study demonstrates the power of the inkjet printing method to produce MSCs on flexible substrates, which have great potential for flexible/wearable electronics.

DLP printing of a flexible micropattern Si/PEDOT:PSS/PEG electrode for lithium-ion batteries

We report on a free-standing 3D-printed Si/PEDOT:PSS/PEG electrode based on silicon nanoparticles (Si) as an active material for lithium-ion batteries (LIBs) that are fabricated by 3D printing via digital light processing (DLP). Compared with the Si electrode prepared by the traditional method, the 3D-printed Si/PEDOT:PSS/PEG electrode developed by DLP preserves a specific discharge capacity of 1658.4 mA h g^-1, with a capacity fade of 0.3% per cycle at a current density of 800 mA g^-1 after 125 cycles. This helps in maintaining its structural integrity and enables it to exhibit significantly high flexibility with an enhanced load of 4.2 mg cm^-2. The resulting free-standing electrode shows that 3D printing has significant potential for application to a variety of LIB technologies.