3D-Printed Lithium-Ion Battery Electrodes: A Brief Review of Three Key Fabrication Techniques

In recent years, 3D printing has emerged as a promising technology in energy storage, particularly for the fabrication of Li-ion battery electrodes. This innovative manufacturing method offers significant material composition and electrode structure flexibility, enabling more complex and efficient designs. While traditional Li-ion battery fabrication methods are well-established, 3D printing opens up new possibilities for enhancing battery performance by allowing for tailored geometries, efficient material usage, and integrating multifunctional components. This article examines three key 3D printing methods for fabricating Li-ion battery electrodes: (1) material extrusion (ME), which encompasses two subcategories-fused deposition modeling (FDM), also referred to as fused filament fabrication (FFF), and direct ink writing (DIW); (2) material jetting (MJ), including inkjet printing (IJP) and aerosol jet printing (AJP) methods; and (3) vat photopolymerization (VAT-P), which includes the stereolithographic apparatus (SLA) subcategory. These methods have been applied in fabricating substrates, thin-film electrodes, and electrolytes for half-cell and full-cell Li-ion batteries. This discussion focuses on their strengths, limitations, and potential advancements for energy storage applications.