In this review, we focus on introducing four mainstream technologies, which have been integrated into the fabrication of currently available battery modules, including IJP, DIW, FDM, and SLA, as illustrated in Figure 1. Additive manufacturing technologies for lithium batteriesĪccording to additive manufacturing technology processes, 3D printing can be divided into the following categories: 1) materials extrusion (e.g., fused deposition modeling and direct ink writing ) 2) directed jetting 3) vat photopolymerization 4) directed energy deposition (DED) 5) binder jetting 6) powder fusion ( Lyu et al., 2021). Finally, special emphasis on challenges and perspective of the practical applications of 3D printing in lithium batteries are also highlighted, aiming to inspire the potential research direction. Secondly, the design principles in raw materials selection, module architecture and printable battery configurations have been systematically discussed. Firstly, several representative 3D printing techniques for battery manufacturing is briefly introduced involving the operation mechanisms, merits and drawbacks. In this review, significant process of 3D printed-lithium batteries has been summarized with a focus on the integration of battery architecture and printing techniques as well as the rational design principles. For lithium batteries, 3D printing can realize novel designs of 3D-architectured electrodes and electrolytes with higher areal-loading densities, larger surface area, and shorter ion diffusion pathways, thus significantly improve both higher areal and volumetric energy densities of lithium batteries. 3D printing has shown great advantages in the fast prototyping of complex configuration with high accuracy, as well as the economic effectiveness due to its intrinsic additive feature with minimal waste, which has been extensively applied in many fields such as micro-electronics, microfluidics, aerospace, and energy storage ( Zhang et al., 2018a). A wide range of materials is applicable for 3D printing ranging from nanoscale to macroscale, such as polymers, metals, and inorganic nanomaterials ( Pang et al., 2020). Therefore, to further optimize the battery performance, it is of great significance to develop precisely controllable method for manufacturing battery devices into 3D hierarchical architectures ( Zhu et al., 2017).Īdditive manufacturing technologies, as generally known as 3D printing, can bestow the manufacturing objects with complex geometry design and precise control ( Prendergast and Burdick, 2020). By contrast, 3D-structured batteries can efficiently utilize the limited space in a compact device that the ionic resistance can be decreased by yielding shorter diffusion pathways and the larger surface areas can significantly facilitate the electrode reaction, generating a higher areal capacitance and energy density ( Chang et al., 2019). Most conventional batteries are made into 2D planar structures, which normally hinder their integration into portable microelectronics due to their large footprint area. With the rapid development of electric vehicles and diverse electronics, the demand for lithium batteries with high energy density and rate capability is increasing ( Zhang et al., 2019 Li et al., 2021). Finally, pertinent insights into the future perspectives of 3D printed lithium batteries have been emphasized, expecting to enlighten the research directions of practical applications of 3D printed batteries. In addition, the general 3D printing design principles in module architectures, materials selection and battery configurations for developing high performance lithium batteries are also systematically discussed. In this review, the latest advances in 3D printed lithium batteries have been summarized with a focus on the fundamentals of representative additive manufacturing techniques involving the operation mechanisms, manufacturing accuracy, respective advantages and challenges.
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