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Fonseca N, Thummalapalli SV, Jambhulkar S, Ravichandran D, Zhu Y, Patil D, Thippanna V, Ramanathan A, Xu W, Guo S, Ko H, Fagade M, Kannan AM, Nian Q, Asadi A, Miquelard-Garnier G, Dmochowska A, Hassan MK, Al-Ejji M, El-Dessouky HM, Stan F, Song K. 3D Printing-Enabled Design and Manufacturing Strategies for Batteries: A Review. SMALL (WEINHEIM AN DER BERGSTRASSE, GERMANY) 2023:e2302718. [PMID: 37501325 DOI: 10.1002/smll.202302718] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/31/2023] [Revised: 07/08/2023] [Indexed: 07/29/2023]
Abstract
Lithium-ion batteries (LIBs) have significantly impacted the daily lives, finding broad applications in various industries such as consumer electronics, electric vehicles, medical devices, aerospace, and power tools. However, they still face issues (i.e., safety due to dendrite propagation, manufacturing cost, random porosities, and basic & planar geometries) that hinder their widespread applications as the demand for LIBs rapidly increases in all sectors due to their high energy and power density values compared to other batteries. Additive manufacturing (AM) is a promising technique for creating precise and programmable structures in energy storage devices. This review first summarizes light, filament, powder, and jetting-based 3D printing methods with the status on current trends and limitations for each AM technology. The paper also delves into 3D printing-enabled electrodes (both anodes and cathodes) and solid-state electrolytes for LIBs, emphasizing the current state-of-the-art materials, manufacturing methods, and properties/performance. Additionally, the current challenges in the AM for electrochemical energy storage (EES) applications, including limited materials, low processing precision, codesign/comanufacturing concepts for complete battery printing, machine learning (ML)/artificial intelligence (AI) for processing optimization and data analysis, environmental risks, and the potential of 4D printing in advanced battery applications, are also presented.
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Affiliation(s)
- Nathan Fonseca
- Manufacturing Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Sri Vaishnavi Thummalapalli
- Manufacturing Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Sayli Jambhulkar
- Systems Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Dharneedar Ravichandran
- Manufacturing Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Yuxiang Zhu
- Manufacturing Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Dhanush Patil
- Manufacturing Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Varunkumar Thippanna
- Manufacturing Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Arunachalam Ramanathan
- Manufacturing Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Weiheng Xu
- Systems Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Shenghan Guo
- Manufacturing Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
- Systems Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Hyunwoong Ko
- Manufacturing Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
- Systems Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Mofe Fagade
- Mechanical Engineering, School of Engineering for Matter, Transport and Energy (SEMTE), Ira A. Fulton Schools of Engineering, Arizona State University, Tempe, AZ, 85281, USA
| | - Arunchala M Kannan
- Fuel Cell Laboratory, The Polytechnic School (TPS), Ira A. Fulton Schools of Engineering, Arizona State University, Mesa, AZ, 85212, USA
| | - Qiong Nian
- School of Engineering for Matter, Transport and Energy (SEMTE), Arizona State University, Tempe, AZ, 85287, USA
| | - Amir Asadi
- Department of Engineering Technology and Industrial Distribution (ETID), Texas A&M University, College Station, TX, 77843, USA
| | - Guillaume Miquelard-Garnier
- Laboratoire PIMM, Arts et Métiers Institute of Technology, CNRS, Cnam, HESAM Universite, 151 Boulevard de l'Hopital, Paris, 75013, France
| | - Anna Dmochowska
- Laboratoire PIMM, Arts et Métiers Institute of Technology, CNRS, Cnam, HESAM Universite, 151 Boulevard de l'Hopital, Paris, 75013, France
| | - Mohammad K Hassan
- Center for Advanced Materials, Qatar University, P.O. BOX 2713, Doha, Qatar
| | - Maryam Al-Ejji
- Center for Advanced Materials, Qatar University, P.O. BOX 2713, Doha, Qatar
| | - Hassan M El-Dessouky
- Physics Department, Faculty of Science, Galala University, Galala City, 43511, Egypt
- Physics Department, Faculty of Science, Mansoura University, Mansoura, 35516, Egypt
| | - Felicia Stan
- Center of Excellence Polymer Processing & Faculty of Engineering, Dunarea de Jos University of Galati, 47 Domneasca Street, Galati, 800008, Romania
| | - Kenan Song
- Manufacturing Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
- Systems Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
- Mechanical Engineering, University of Georgia, 302 E. Campus Rd, Athens, Georgia, 30602, United States
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Kotz F, Mader M, Dellen N, Risch P, Kick A, Helmer D, Rapp BE. Fused Deposition Modeling of Microfluidic Chips in Polymethylmethacrylate. MICROMACHINES 2020; 11:mi11090873. [PMID: 32961823 PMCID: PMC7570108 DOI: 10.3390/mi11090873] [Citation(s) in RCA: 31] [Impact Index Per Article: 7.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 08/20/2020] [Revised: 09/16/2020] [Accepted: 09/18/2020] [Indexed: 12/26/2022]
Abstract
Polymethylmethacrylate (PMMA) is one of the most important thermoplastic materials and is a widely used material in microfluidics. However, PMMA is usually structured using industrial scale replication processes, such as hot embossing or injection molding, not compatible with rapid prototyping. In this work, we demonstrate that microfluidic chips made from PMMA can be 3D printed using fused deposition modeling (FDM). We demonstrate that using FDM microfluidic chips with a minimum channel cross-section of ~300 µm can be printed and a variety of different channel geometries and mixer structures are shown. The optical transparency of the chips is shown to be significantly enhanced by printing onto commercial PMMA substrates. The use of such commercial PMMA substrates also enables the integration of PMMA microstructures into the printed chips, by first generating a microstructure on the PMMA substrates, and subsequently printing the PMMA chip around the microstructure. We further demonstrate that protein patterns can be generated within previously printed microfluidic chips by employing a method of photobleaching. The FDM printing of microfluidic chips in PMMA allows the use of one of microfluidics' most used industrial materials on the laboratory scale and thus significantly simplifies the transfer from results gained in the lab to an industrial product.
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Affiliation(s)
- Frederik Kotz
- Laboratory of Process Engineering, NeptunLab, Department of Microsystems Engineering (IMTEK), University of Freiburg, 79110 Freiburg, Germany; (M.M.); (N.D.); (P.R.); (A.K.); (D.H.); (B.E.R.)
- Freiburg Materials Research Center (FMF), University of Freiburg, 79104 Freiburg im Breisgau, Germany
- Correspondence: ; Tel.: +49-761-203-7355
| | - Markus Mader
- Laboratory of Process Engineering, NeptunLab, Department of Microsystems Engineering (IMTEK), University of Freiburg, 79110 Freiburg, Germany; (M.M.); (N.D.); (P.R.); (A.K.); (D.H.); (B.E.R.)
| | - Nils Dellen
- Laboratory of Process Engineering, NeptunLab, Department of Microsystems Engineering (IMTEK), University of Freiburg, 79110 Freiburg, Germany; (M.M.); (N.D.); (P.R.); (A.K.); (D.H.); (B.E.R.)
| | - Patrick Risch
- Laboratory of Process Engineering, NeptunLab, Department of Microsystems Engineering (IMTEK), University of Freiburg, 79110 Freiburg, Germany; (M.M.); (N.D.); (P.R.); (A.K.); (D.H.); (B.E.R.)
| | - Andrea Kick
- Laboratory of Process Engineering, NeptunLab, Department of Microsystems Engineering (IMTEK), University of Freiburg, 79110 Freiburg, Germany; (M.M.); (N.D.); (P.R.); (A.K.); (D.H.); (B.E.R.)
| | - Dorothea Helmer
- Laboratory of Process Engineering, NeptunLab, Department of Microsystems Engineering (IMTEK), University of Freiburg, 79110 Freiburg, Germany; (M.M.); (N.D.); (P.R.); (A.K.); (D.H.); (B.E.R.)
- Freiburg Materials Research Center (FMF), University of Freiburg, 79104 Freiburg im Breisgau, Germany
- FIT Freiburg Center of Interactive Materials and Bioinspired Technologies, University of Freiburg, 79110 Freiburg im Breisgau, Germany
| | - Bastian E. Rapp
- Laboratory of Process Engineering, NeptunLab, Department of Microsystems Engineering (IMTEK), University of Freiburg, 79110 Freiburg, Germany; (M.M.); (N.D.); (P.R.); (A.K.); (D.H.); (B.E.R.)
- Freiburg Materials Research Center (FMF), University of Freiburg, 79104 Freiburg im Breisgau, Germany
- FIT Freiburg Center of Interactive Materials and Bioinspired Technologies, University of Freiburg, 79110 Freiburg im Breisgau, Germany
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