3D printing is a disruptive technology that is changing the manufacturing industry and is set to revolutionize several other sectors, including energy storage. This printing technology enables the fabrication of complex geometries and designs that are not possible with conventional manufacturing methods. The use of 3D printing for electrochemical energy storage (ECES) applications has numerous benefits. There are various ECES technologies in use today, each with their own pros and cons, and 3D printing can be applied to manufacture electrodes that overcome current performance limitations, reduce costs and expand adoption of these energy storage devices. This article discusses various ECES technologies, as well as the ways in which 3D printing can be used to expedite adoption of each.

What is 3D printing?

In this manufacturing process, an object is created by building successive layers of material. A 3D printer has three primary components: a computer, a feedstock and a fabrication unit. The computer controls the fabrication unit and instructs it on how and what to build. The feedstock is the raw material that is fed into the fabrication unit. It is typically fed through a spool, but other configurations are also possible. The layers of feedstock are built on top of each other until a finished product is synthesized.

The primary benefit of 3D printing is that it enables the fabrication of complex geometries and designs that are not possible with conventional manufacturing methods. 3D printing can be used to produce almost any part, from aerospace grade materials to sandals. It is particularly useful for prototyping and custom manufacturing, as it is easy and fast to set up and can produce a wide variety of shapes and sizes.

What are ECES systems?

ECES systems use chemical reactions to generate electricity. Solid-state electrolytes (SSEs) are highly conductive materials that separate the electrodes in some ECES such as lithium-ion. They are typically made from a liquid polymer but can also be made from other materials. There are several challenges with using liquid electrolytes in ECES applications. First, these materials change their composition during operation, which changes the amount of resistance in the system. Second, the use of liquid electrolytes requires inclusion of an electrolyte separator, which increases the size and weight of the ECES system. Third, liquid electrolytes require the use of electrochemical cells, which are more difficult and expensive to scale up.

SSEs are used in solid-state batteries (SSBs), which can be made in different shapes and sizes, and do not require an electrolyte separator or electrochemical cells. This makes them easier and cheaper to scale up than liquid-based ECES. SSBs can be used to replace lithium-ion batteries in portable electronics, as well as to store renewable energy.

3D printing for lithium-ion batteries

In these batteries, lithium ions move back and forth between anode- and cathode-side electrodes in the electrolyte, storing and discharging energy. 3D printing can be used to manufacture electrodes for these batteries, based on lithium metal oxide materials that are mixed with a binder and other additives. They are then formed into a desired shape using hot pressing or injection molding. The fabrication of electrodes for lithium-ion batteries could lead to cost reductions and expanded adoption of these ECES devices.

3D printing for lithium-air batteries

Lithium-air batteries use oxygen from the air to discharge electricity. While they offer high power and energy capacities, these units are limited by low efficiencies because of the difficulty in releasing the stored oxygen from the electrodes. With 3D printing, the electrodes are made from carbon nanomaterials that are mixed with binders and other additives and are then formed into a desired shape using hot pressing or injection molding.

3D printing for lithium-metal batteries

Lithium-metal batteries have high energy density and energy efficiency, but poor power density. 3D printing can be used to manufacture electrodes for lithium-metal batteries based on lithium metal oxides, carbon nanomaterials and binders. They are formed into a desired shape using hot pressing or injection molding.

3D printing for metal-air batteries

Metal-air batteries use oxygen from the air as the electrolyte, making them safer than lithium-based ECES. They have lower energy densities than lithium-based batteries but are more environmentally friendly. Similar to previously discussed battery types, 3D printing can be used to manufacture electrodes for metal-air batteries.

[Browse suppliers of 3D printers and additive manufacturing equipment on GlobalSpec.com]

Conclusion

3D printing has been a game changer for a variety of industries, with the potential to transform everything by accelerating product development and lowering cost. However, until now there were few examples of how 3D printing could impact the energy storage industry. With 3D printing technology continuing to advance, it’s becoming an increasingly viable option for production in almost any industry.