ADVANCED MATERIALS & PROCESSES | APRIL 2024 24 In the ever-evolving landscape of advanced materials and processes, additive manufacturing has emerged as a game-changer, pushing the boundaries of what is possible across countless industries. One sector that stands to benefit significantly from the revolutionary capabilities of additive manufacturing (AM) is energy storage, specifically the field of rechargeable batteries[1,2]. This article delves into the technical aspects supporting the opinion that AM holds the key to unlocking unprecedented advancements in battery design and performance, and also discusses the upcoming challenges to make it a reality. BREAKING TRADITIONAL MANUFACTURING BOUNDARIES Traditional lithium-ion battery manufacturing, involving roll-to-roll electrodes tape casting, calendering, and stacking of the components, is a well-established and reliable method to produce 2D planar geometry configurations[3]. Components are either assembled into pouch and prismatic cells, or rolled into cylindrical cells[4], thus limiting innovation in terms of co-design with the devices. By breaking free from traditional manufacturing constraints, additive manufacturing, also known as 3D printing, not only redefines individual battery components production, but also expands the PERSPECTIVE THE TRANSFORMATIVE POWER OF ADDITIVE MANUFACTURING FOR BATTERIES The benefits and flexibility of using additive manufacturing opens up new possibilities for lithium-ion batteries beyond the limitations of traditional methods. Ana C. Martínez and Alexis Maurel, The University of Texas at El Paso Fig. 1 — Example of a smartwatch where a shape-conformable battery can be integrated into the complete frame thanks to additive manufacturing. the production of complex separator/ electrolyte geometries and intricate electrode structures, such as 3D lattices, that are otherwise unattainable through standard manufacturing methods[6]. This newfound freedom in design, combined with the capabilities of multi-material printing options, enables the development of interdigitated 3D electrode designs that have been shown through modeling studies to result in enhanced specific surface area, improved ionic diffusion, and improved electrochemical power performance[7,8]. One of the standout advantages of AM is the ability to accurately control material deposition, from the macroscale for the material extrusion processes (e.g., fused deposition modeling and direct ink writing), to microscale for binder jetting, inkjet printing, powder possibilities for complete 3D battery integration into diverse applications[2]. The versatility of additive manufacturing allows for the customization of batteries to meet specific design requirements: whether it is a small-scale, high- performance battery for portable electronic devices or a large- format battery pack for electric vehicles, AM empowers engineers to design and produce energy storage solutions tailored to the unique needs of each application. This flexibility enables design efficiency by utilizing what was once considered dead space, and replacing it with shape-conformable batteries[2]. In the automotive industry, the contours of a vehicle chassis could potentially be utilized to seamlessly integrate batteries. Another example is smartwatches (Fig. 1) where the battery could be located not only inside the case, but also within the bracelet[5]. This innovative approach marks a departure from conventional design limitations and highlights the potential for additive manufacturing to shape the future of energy storage solutions. Additive manufacturing also introduces a paradigm shift by enabling
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