FFF/FDM 3D-Printed Solid Polymer Electrolytes Based on Acrylonitrile Copolymers for Lithium-Ion Batteries

Lithium-ion batteries (LIBs) are essential in modern electronics, particularly in portable devices and electric vehicles. However, the limited design flexibility of current battery shapes constrains the development of custom-sized power sources for advanced applications like wearable electronics and medical devices. Additive manufacturing (AM), specifically Fused Filament Fabrication (FFF), presents a promising solution by enabling the creation of batteries with customized shapes. This study explores the use of novel poly(acrylonitrile-co-polyethylene glycol methyl ether acrylate) (poly(AN-co-PEGMEA)) copolymers as solid polymer electrolytes for lithium-ion batteries, optimized for 3D printing using FFF. The copolymers were synthesized with varying AN:PEGMEA ratios, and their physical, thermal, and electrochemical properties were systematically characterized. The study found that a poly(AN-co-PEGMEA) 6:1 copolymer ratio offers an optimal balance between printability and ionic conductivity. The successful extrusion of filaments and subsequent 3D printing of complex shapes demonstrate the potential of these materials for next-generation battery designs. The addition of succinonitrile (SCN) as a plasticizer significantly improved ionic conductivity and lithium cation transference numbers, making these copolymers viable for practical applications. This work highlights the potential of combining polymer chemistry with additive manufacturing to provide new opportunities in lithium-ion battery design and function.