Structured Electrode Additive Manufacturing for Lithium-Ion Batteries

As the world increasingly swaps fossil fuels, significant advances in lithium-ion batteries have occurred over the past decade. Though demand for increased energy density with mechanical stability continues to be strong, attempts to use traditional ink-casting to increase electrode thickness or geometric complexity have had limited success. Here, we combined a nanomaterial orientation with 3D printing and developed a dry electrode processing route, structured electrode additive manufacturing (SEAM), to rapidly fabricate thick electrodes with an out-of-plane aligned architecture with low tortuosity and mechanical robustness. SEAM uses a shear flow of molten feedstock to control the orientation of the anisotropic materials across nano to macro scales, favoring Li-ion transport and insertion. These structured electrodes with 1 mm thickness have more than twice the specific capacity at 1 C compared to slurry-cast electrodes and have higher mechanical properties (compressive strength of 0.84 MPa and modulus of 5 MPa) than other reported 3D-printed electrodes.