Additive Manufacturing of Batteries

Additive manufacturing, i.e., 3D printing, is being increasingly utilized to fabricate a variety of complex-shaped electronics and energy devices (e.g., batteries, supercapacitors, and solar cells) due to its excellent process flexibility, good geometry controllability, as well as cost and material waste reduction. In this review, the recent advances in 3D printing of emerging batteries are emphasized and discussed. The recent progress in fabricating 3D-printed batteries through the major 3D-printing methods, including lithographybased 3D printing, template-assisted electrodeposition-based 3D printing, inkjet printing, direct ink writing, fused deposition modeling, and aerosol jet printing, are first summarized. Then, the significant achievements made in the development and printing of battery electrodes and electrolytes are highlighted. Finally, major challenges are discussed and potential research frontiers in developing 3D-printed batteries are proposed. It is expected that with the continuous development of printing techniques and materials, 3D-printed batteries with long-term durability, favorable safety as well as high energy and power density will eventually be widely used in many fields.

[1]  Aaron D. Franklin,et al.  Improving Contact Interfaces in Fully Printed Carbon Nanotube Thin-Film Transistors. , 2016, ACS nano.

[2]  P. Chahal,et al.  Printed Diodes: Materials Processing, Fabrication, and Applications , 2019, Advanced science.

[3]  Brian Derby,et al.  Bioprinting: Inkjet printing proteins and hybrid cell-containing materials and structures , 2008 .

[4]  Kaufui Wong,et al.  A Review of Additive Manufacturing , 2012 .

[5]  Jin-Woo Choi,et al.  Inkjet Printing of Carbon Nanotubes , 2013, Nanomaterials.

[6]  James W. Evans,et al.  Direct write dispenser printing of a zinc microbattery with an ionic liquid gel electrolyte , 2010 .

[7]  Y. B. Chen,et al.  Enhanced electrochromic properties of ordered porous nickel oxide thin film prepared by self-assembled colloidal crystal template-assisted electrodeposition , 2011 .

[8]  Paul V Braun,et al.  High-power lithium ion microbatteries from interdigitated three-dimensional bicontinuous nanoporous electrodes , 2013, Nature Communications.

[9]  Benji Maruyama,et al.  Composite batteries: a simple yet universal approach to 3D printable lithium-ion battery electrodes , 2016 .

[10]  L. Francis,et al.  Optimization of aerosol jet printing for high-resolution, high-aspect ratio silver lines. , 2013, ACS applied materials & interfaces.

[11]  Rigoberto C. Advincula,et al.  3D Printing of Polymer Nanocomposites via Stereolithography , 2017 .

[12]  John T. Vaughey,et al.  Rechargeable Ca-Ion Batteries: A New Energy Storage System , 2015 .

[13]  Feng Xu,et al.  3D Printing Technologies for Flexible Tactile Sensors toward Wearable Electronics and Electronic Skin , 2018, Polymers.

[14]  Martin Pumera,et al.  3D-printing technologies for electrochemical applications. , 2016, Chemical Society reviews.

[15]  L. Archer,et al.  Porous hollow carbon@sulfur composites for high-power lithium-sulfur batteries. , 2011, Angewandte Chemie.

[16]  Zhiyu Jiang,et al.  Electrochemical properties of LiCoO2 thin film electrode prepared by ink-jet printing technique , 2008 .

[17]  Wei Jiang,et al.  3D Printable Graphene Composite , 2015, Scientific Reports.

[18]  Aaron D. Price,et al.  Toward a remarkable Li-S battery via 3D printing , 2019, Nano Energy.

[19]  Sylvie Grugeon,et al.  Highly Loaded Graphite–Polylactic Acid Composite-Based Filaments for Lithium-Ion Battery Three-Dimensional Printing , 2018, Chemistry of Materials.

[20]  Yayue Pan,et al.  Elevated‐Temperature 3D Printing of Hybrid Solid‐State Electrolyte for Li‐Ion Batteries , 2018, Advanced materials.

[21]  K. Kardel,et al.  Organic Solar Cell by Inkjet Printing—An Overview , 2017 .

[22]  David E.J. Armstrong,et al.  Hybrid electrolytes with 3D bicontinuous ordered ceramic and polymer microchannels for all-solid-state batteries , 2018 .

[23]  Zheng Jia,et al.  Anomalous scaling law of strength and toughness of cellulose nanopaper , 2015, Proceedings of the National Academy of Sciences.

[24]  Tai Ma,et al.  Fully printed, high energy density flexible zinc-air batteries based on solid polymer electrolytes and a hierarchical catalyst current collector , 2019, Flexible and Printed Electronics.

[25]  J. Lewis,et al.  3D Printing of Customized Li‐Ion Batteries with Thick Electrodes , 2018, Advanced materials.

[26]  Alexandra L. Rutz,et al.  Three-dimensional printing of high-content graphene scaffolds for electronic and biomedical applications. , 2015, ACS nano.

[27]  M. Armand,et al.  Issues and challenges facing rechargeable lithium batteries , 2001, Nature.

[28]  John A Rogers,et al.  Holographic patterning of high-performance on-chip 3D lithium-ion microbatteries , 2015, Proceedings of the National Academy of Sciences.

[29]  Guangmin Zhou,et al.  Progress in flexible lithium batteries and future prospects , 2014 .

[30]  Dominique Guyomard,et al.  Toward fast and cost-effective ink-jet printing of solid electrolyte for lithium microbatteries , 2015 .

[31]  Benji Maruyama,et al.  3D Printable Ceramic–Polymer Electrolytes for Flexible High‐Performance Li‐Ion Batteries with Enhanced Thermal Stability , 2017 .

[32]  Boyang Liu,et al.  Extrusion‐Based 3D Printing of Hierarchically Porous Advanced Battery Electrodes , 2018, Advanced materials.

[33]  Joong Tark Han,et al.  3D Printing of Reduced Graphene Oxide Nanowires , 2015, Advanced materials.

[34]  A. Franklin,et al.  Completely Printed, Flexible, Stable, and Hysteresis‐Free Carbon Nanotube Thin‐Film Transistors via Aerosol Jet Printing , 2017 .

[35]  Yu Song,et al.  All-solid-state Al–air batteries with polymer alkaline gel electrolyte , 2014 .

[36]  Tianyu Liu,et al.  3D printed functional nanomaterials for electrochemical energy storage , 2017 .

[37]  Fan Zhang,et al.  A Novel Aluminum–Graphite Dual‐Ion Battery , 2016 .

[38]  Xueliang Sun,et al.  Toward High Areal Energy and Power Density Electrode for Li-Ion Batteries via Optimized 3D Printing Approach. , 2018, ACS applied materials & interfaces.

[39]  Xian‐Xiang Zeng,et al.  Recent Advancements in Polymer-Based Composite Electrolytes for Rechargeable Lithium Batteries , 2018, Electrochemical Energy Reviews.

[40]  Diana Golodnitsky,et al.  Novel rechargeable 3D-Microbatteries on 3D-printed-polymer substrates: Feasibility study , 2018 .

[41]  Howon Lee,et al.  Design and optimization of a light-emitting diode projection micro-stereolithography three-dimensional manufacturing system. , 2012, The Review of scientific instruments.

[42]  Feng Zhang,et al.  3D Printing of Graphene Aerogels. , 2016, Small.

[43]  Shanhui Fan,et al.  Direct‐Write Assembly of Three‐Dimensional Photonic Crystals: Conversion of Polymer Scaffolds to Silicon Hollow‐Woodpile Structures , 2006 .

[44]  Kyung-In Jang,et al.  3D multifunctional integumentary membranes for spatiotemporal cardiac measurements and stimulation across the entire epicardium , 2014, Nature Communications.

[45]  Xiaogang Han,et al.  3D‐Printed All‐Fiber Li‐Ion Battery toward Wearable Energy Storage , 2017 .

[46]  George Kenanakis,et al.  3D printed graphene-based electrodes with high electrochemical performance , 2017 .

[47]  Yanhai Du,et al.  Review on fabrication techniques for porous electrodes of solid oxide fuel cells by sacrificial template methods , 2017 .

[48]  Feng Zhang,et al.  3D printing technologies for electrochemical energy storage , 2017 .

[49]  Sung‐Gyu Park,et al.  Holographic Fabrication of 3D Nanostructures , 2018, Advanced Materials Interfaces.

[50]  M. Wagemaker,et al.  Facile Micro Templating LiFePO4 Electrodes for High Performance Li‐Ion Batteries , 2013 .

[51]  Liangbing Hu,et al.  3D‐Printing Electrolytes for Solid‐State Batteries , 2018, Advanced materials.

[52]  Abdullah Khan,et al.  Silica Nanoparticle-Induced Structural Reorganizations in Pulmonary Surfactant Films: What Monolayer Compression Isotherms Do Not Say , 2018, ACS Applied Nano Materials.

[53]  A. Manthiram,et al.  Challenges and prospects of lithium-sulfur batteries. , 2013, Accounts of chemical research.

[54]  S. Jiao,et al.  A new aluminium-ion battery with high voltage, high safety and low cost. , 2015, Chemical communications.

[55]  Yulong Liu,et al.  Inkjet-printed silicon as high performance anodes for Li-ion batteries , 2017 .

[56]  Dou Zhang,et al.  3D‐Printed Microelectrodes with a Developed Conductive Network and Hierarchical Pores toward High Areal Capacity for Microbatteries , 2018, Advanced Materials Technologies.

[57]  Diana Golodnitsky,et al.  Towards smart free form-factor 3D printable batteries , 2018 .

[58]  B. McCloskey,et al.  Lithium−Air Battery: Promise and Challenges , 2010 .

[59]  Ananth Dodabalapur,et al.  Inkjet-Printed Lithium-Sulfur Microcathodes for All-Printed, Integrated Nanomanufacturing. , 2017, Small.

[60]  Bora Yoon,et al.  Inkjet Printing of Conjugated Polymer Precursors on Paper Substrates for Colorimetric Sensing and Flexible Electrothermochromic Display , 2011, Advanced materials.

[61]  Hong Yee Low,et al.  3D-Printed, Carbon-Nanotube-Wrapped, Thermoresponsive Polymer Spheres for Safer Lithium-Ion Batteries , 2018, Energy Technology.

[62]  Sunil C. Joshi,et al.  3D printing in aerospace and its long-term sustainability , 2015 .

[63]  Rui Zhang,et al.  Toward Safe Lithium Metal Anode in Rechargeable Batteries: A Review. , 2017, Chemical reviews.

[64]  L. Nazar,et al.  Sodium and sodium-ion energy storage batteries , 2012 .

[65]  Jonghyun Park,et al.  3D printed hierarchically-porous microlattice electrode materials for exceptionally high specific capacity and areal capacity lithium ion batteries , 2018, Additive Manufacturing.

[66]  Changyong Liu,et al.  Fabrication and Characterization of 3D-Printed Highly-Porous 3D LiFePO4 Electrodes by Low Temperature Direct Writing Process , 2017, Materials.

[67]  Frederik L. Giesel,et al.  3D printing based on imaging data: review of medical applications , 2010, International Journal of Computer Assisted Radiology and Surgery.

[68]  D. Aurbach,et al.  Review on Li‐Sulfur Battery Systems: an Integral Perspective , 2015 .

[69]  Dominique Guyomard,et al.  Ink-jet printed porous composite LiFePO4 electrode from aqueous suspension for microbatteries , 2015 .

[70]  Tian Li,et al.  Graphene Oxide‐Based Electrode Inks for 3D‐Printed Lithium‐Ion Batteries , 2016, Advanced materials.

[71]  Chao Gao,et al.  Direct 3D Printing of Ultralight Graphene Oxide Aerogel Microlattices , 2018 .

[72]  Bin Li,et al.  3D-Printed Hierarchical Porous Frameworks for Sodium Storage. , 2017, ACS applied materials & interfaces.

[73]  I. Park,et al.  Stretchable, Skin‐Mountable, and Wearable Strain Sensors and Their Potential Applications: A Review , 2016 .

[74]  Thomas A. Campbell,et al.  3D printing of multifunctional nanocomposites , 2013 .

[75]  Zhenan Bao,et al.  Skin-inspired electronic devices , 2014 .

[76]  Jian Wang,et al.  3D printing of hybrid MoS2-graphene aerogels as highly porous electrode materials for sodium ion battery anodes , 2019, Materials & Design.

[77]  M. Lundstrom,et al.  Ballistic carbon nanotube field-effect transistors , 2003, Nature.

[78]  Bethany C Gross,et al.  Evaluation of 3D printing and its potential impact on biotechnology and the chemical sciences. , 2014, Analytical chemistry.

[79]  Hongli Zhu,et al.  3D Printed High‐Performance Lithium Metal Microbatteries Enabled by Nanocellulose , 2019, Advanced materials.

[80]  Jiulin Wang,et al.  Efficient Storing Energy Harvested by Triboelectric Nanogenerators Using a Safe and Durable All‐Solid‐State Sodium‐Ion Battery , 2017, Advanced science.

[81]  E. Secor.  Principles of aerosol jet printing , 2018, Flexible and Printed Electronics.

[82]  J. Lewis,et al.  Direct writing in three dimensions , 2004 .

[83]  Ryan B. Wicker,et al.  Fabrication of 3D Biocompatible/Biodegradable Micro-Scaffolds Using Dynamic Mask Projection Microstereolithography , 2009 .

[84]  John Wang,et al.  3D‐Printed MOF‐Derived Hierarchically Porous Frameworks for Practical High‐Energy Density Li–O2 Batteries , 2018, Advanced Functional Materials.

[85]  Bin Li,et al.  3D Printing Sulfur Copolymer‐Graphene Architectures for Li‐S Batteries , 2018 .

[86]  Christine Ho,et al.  Perspectives on Energy Storage for Flexible Electronic Systems , 2015, Proceedings of the IEEE.

[87]  Michael Rottmayer,et al.  High Capacity Rate Capable Aerosol Jet Printed Li‐Ion Battery Cathode , 2019, Advanced Engineering Materials.

[88]  Iskander S. Akhatov,et al.  A Review on Aerosol-Based Direct-Write and Its Applications for Microelectronics , 2012 .

[89]  Chee Kai Chua,et al.  Emerging 3D‐Printed Electrochemical Energy Storage Devices: A Critical Review , 2017 .

[90]  Matthew J. Catenacci,et al.  Fully Printed Memristors from Cu–SiO2 Core–Shell Nanowire Composites , 2017, 2017 75th Annual Device Research Conference (DRC).

[91]  A. Prowald,et al.  Template-assisted electrodeposition of highly ordered macroporous zinc structures from an ionic liquid , 2013, Journal of Solid State Electrochemistry.

[92]  Young Hee Lee,et al.  Electrochemical Properties of High-Power Supercapacitors Using Single-Walled Carbon Nanotube Electrodes , 2001 .

[93]  Arumugam Manthiram,et al.  Printed microelectrodes for scalable, high-areal-capacity lithium-sulfur batteries. , 2016, Chemical communications.

[94]  Bin Li,et al.  Continuously 3D printed quantum dot-based electrodes for lithium storage with ultrahigh capacities , 2018 .

[95]  Keun-Ho Choi,et al.  Current Status and Challenges in Printed Batteries: Toward Form Factor-Free, Monolithic Integrated Power Sources , 2018 .

[96]  P. Soman,et al.  Fabrication of conductive polyaniline hydrogel using porogen leaching and projection microstereolithography. , 2015, Journal of materials chemistry. B.

[97]  Jiangtao Hu,et al.  3D‐Printed Cathodes of LiMn1−xFexPO4 Nanocrystals Achieve Both Ultrahigh Rate and High Capacity for Advanced Lithium‐Ion Battery , 2016 .

[98]  Yan Zhang,et al.  3D Printed Graphene Based Energy Storage Devices , 2017, Scientific Reports.

[99]  J. A. Lewis.  Direct Ink Writing of 3D Functional Materials , 2006 .

[100]  Juan Carlos Ruiz-Morales,et al.  Three dimensional printing of components and functional devices for energy and environmental applications , 2017 .

[101]  L. Nazar,et al.  Advances in Li–S batteries , 2010 .

[102]  J. Lewis,et al.  Device fabrication: Three-dimensional printed electronics , 2015, Nature.

[103]  Peter Enoksson,et al.  Solidification of 3D Printed Nanofibril Hydrogels into Functional 3D Cellulose Structures , 2016 .

[104]  Kejie Zhao,et al.  Printing 3D Gel Polymer Electrolyte in Lithium-Ion Microbattery Using Stereolithography , 2017 .

[105]  M. Piszcz,et al.  Electrolytes for Li-ion transport – Review , 2015 .

[106]  Jean-Marie Tarascon,et al.  Li-O2 and Li-S batteries with high energy storage. , 2011, Nature materials.

[107]  J. Howard,et al.  Characterization of microporous separators for lithium-ion batteries , 1999 .

[108]  Yuji Suzuki,et al.  Fabrication of Three-Dimensional Battery Using Ceramic Electrolyte with Honeycomb Structure by Sol–Gel Process , 2010 .

[109]  Zhiyu Jiang,et al.  A novel and facile route of ink-jet printing to thin film SnO2 anode for rechargeable lithium ion batteries , 2006 .

[110]  Steven D. Lacey,et al.  Nanocellulose as green dispersant for two-dimensional energy materials , 2015 .

[111]  Seok-Hee Lee,et al.  Cross-section segmentation for improving the shape accuracy of microstructure array in projection microstereolithography , 2010 .

[112]  D. J. Lee,et al.  Composite protective layer for Li metal anode in high-performance lithium–oxygen batteries , 2014 .

[113]  Haoshen Zhou,et al.  A reversible long-life lithium–air battery in ambient air , 2013, Nature Communications.

[114]  Shu Yang,et al.  Creating Three‐Dimensional Polymeric Microstructures by Multi‐Beam Interference Lithography , 2005 .

[115]  M. Gedvilas,et al.  Fabrication of periodic micro-structures by holographic lithography , 2013 .

[116]  M. R. Palacín,et al.  Towards a calcium-based rechargeable battery. , 2016, Nature materials.

[117]  Xinhua Liang,et al.  Macro-/Micro-Controlled 3D Lithium-Ion Batteries via Additive Manufacturing and Electric Field Processing , 2018, Scientific Reports.

[118]  Liangbing Hu,et al.  3D‐Printed Graphene Oxide Framework with Thermal Shock Synthesized Nanoparticles for Li‐CO2 Batteries , 2018, Advanced Functional Materials.

[119]  S. Cho,et al.  Fast electrochemistry of conductive polymer nanotubes: synthesis, mechanism, and application. , 2008, Accounts of chemical research.

[120]  Paul V. Braun,et al.  Three-dimensional bicontinuous ultrafast-charge and -discharge bulk battery electrodes. , 2011, Nature nanotechnology.

[121]  Zhuxian Yang,et al.  Preparation of 3D graphene-based architectures and their applications in supercapacitors , 2015 .

[122]  JongTae Yoo,et al.  Flexible/shape-versatile, bipolar all-solid-state lithium-ion batteries prepared by multistage printing , 2018 .

[123]  Alessandro Chiolerio,et al.  Wearable Electronics and Smart Textiles: A Critical Review , 2014, Sensors.

[124]  M. R. Palacín,et al.  On the road toward calcium-based batteries , 2018, Current Opinion in Electrochemistry.

[125]  A. Kashani,et al.  Additive manufacturing (3D printing): A review of materials, methods, applications and challenges , 2018, Composites Part B: Engineering.

[126]  K. W. Chew.  Development of Novel Bio-Degradable Electrolyte Based on Polylactide (PLA) for Lithium Rechargeable Battery , 2013 .

[127]  Stefan W. Glunz,et al.  Metal aerosol jet printing for solar cell metallization , 2007 .

[128]  P. Bruce,et al.  A Reversible and Higher-Rate Li-O2 Battery , 2012, Science.

[129]  Daniel A. Steingart,et al.  A super ink jet printed zinc–silver 3D microbattery , 2009 .

[130]  Donghan Kim,et al.  Sodium‐Ion Batteries , 2013 .

[131]  Bhesh Bhandari,et al.  3d printing technologies applied for food design: Status and prospects , 2016 .

[132]  Konstantinos G. Dassios,et al.  3D printed electrochemical energy storage devices , 2019, Journal of Materials Chemistry A.

[133]  Won Suk Chang,et al.  Three-Dimensional Printing of Highly Conductive Carbon Nanotube Microarchitectures with Fluid Ink. , 2016, ACS nano.

[134]  John F. Federici,et al.  Fabrication of rechargeable lithium ion batteries using water-based inkjet printed cathodes , 2015 .

[135]  J. Lewis,et al.  3D Printing of Interdigitated Li‐Ion Microbattery Architectures , 2013, Advanced materials.

[136]  S. Qu,et al.  Recent Advances in Stretchable Supercapacitors Enabled by Low-Dimensional Nanomaterials. , 2018, Small.

[137]  Wei Zhang,et al.  Aerosol jet printed, low voltage, electrolyte gated carbon nanotube ring oscillators with sub-5 μs stage delays. , 2013, Nano letters.

[138]  H. Du,et al.  Inkjet-printed optoelectronics. , 2017, Nanoscale.