Laser-based three-dimensional manufacturing technologies for rechargeable batteries

3D Printing Manufacturing of Lithium Batteries: Prospects and Challenges toward Practical Applications

The manufacturing and assembly of components within cells have a direct impact on the sample performance. Conventional processes restrict the shapes, dimensions, and structures of the commercially available batteries. 3D printing, a novel manufacturing process for precision and practicality, is expected to revolutionize the lithium battery industry owing to its advantages of customization, mechanization, and intelligence. This technique can be used to effectively construct intricate 3D structures that enhance the designability, integrity, and electrochemical performance of both liquid- and solid-state lithium batteries. In this study, an overview of the development of 3D printing technologies is provided and their suitability for comparison with conventional printing processes is assessed. Various 3D printing technologies applicable to lithium-ion batteries have been systematically introduced, especially more practical composite printing technologies. The practicality, limitations, and optimization of 3D printing are discussed dialectically for various battery modules, including electrodes, electrolytes, and functional architectures. In addition, all-printed batteries are emphatically introduced. Finally, the prospects and challenges of 3D printing in the battery industry are evaluated.

Electrochemical Properties of Laser-Printed Multilayer Anodes for Lithium-Ion Batteries

New electrode architectures promise huge potential for improving batteries' electrochemical properties, such as power density, energy density, and lifetime. In this work, the use of laser-induced forward transfer (LIFT) was employed and evaluated as a tool for the development of advanced electrode architectures. For this purpose, it was first confirmed that the printing process has no effect on the transferred battery material by comparing the electrochemical performance of the printed anodes with state-of-the-art coated ones. For this, polyvinylidene fluoride (PVDF) was used as a binder and n-methyl-2-pyrrolidone (NMP) as a solvent, which is reported to be printable. Subsequently, multilayer electrodes with flake-like and spherical graphite particles were printed to test if a combination of their electrochemical related properties can be realized with measured specific capacities ranging from 321 mAh·g-1 to 351 mAh·g-1. Further, a multilayer anode design with a silicon-rich intermediate layer was printed and electrochemically characterized. The initial specific capacity was found to be 745 mAh·g-1. The presented results show that the LIFT technology offers the possibility to generate alternative electrode designs, promoting research in the optimization of 3D battery systems.