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Updated: Sep 16, 2025

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Solid-to-Solid Manufacturing Processes for High-Performance Li-Ion Solid-State Batteries.

David Orisekeh1, Byeong-Min Roh2, Xinyi Xiao1

  • 1Department of Mechanical Engineering, University of North Texas, Denton, TX 76205, USA.

Polymers
|July 12, 2025
PubMed
Summary
This summary is machine-generated.

Researchers developed a 3D-printed solid-state electrolyte using polylactic acid (PLA) and lithium hexafluorophosphate (LiPF6). This innovative method creates robust, ionically conductive separators for solid-state batteries (SSBs) with enhanced performance and recyclability.

Keywords:
additive manufacturingelectrodeionic conductivitymechanical propertypolymerseparatorsolid electrolytesolid-state battery

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Area of Science:

  • Materials Science
  • Electrochemistry
  • Additive Manufacturing

Background:

  • Solid-state batteries (SSBs) are crucial for advanced energy storage, replacing liquid electrolytes with solid separators for improved safety and stability.
  • Current manufacturing methods for solid separators often involve complex processes and may not be cost-effective or environmentally friendly.

Purpose of the Study:

  • To investigate the additive manufacturing of solid-state electrolytes (SSEs) using fused deposition modeling (FDM) with recyclable polylactic acid (PLA).
  • To precisely control macro-porosity and create tunable pore networks for enhanced ionic conductivity.
  • To develop a cost-efficient, mechanically robust, and recyclable composite separator for SSBs.

Main Methods:

  • Utilized fused deposition modeling (FDM) with PLA filaments to 3D print porous polymer scaffolds.
  • Controlled macro-porosity by varying process parameters like raster orientation and infill percentage.
  • Infiltrated printed scaffolds with lithium hexafluorophosphate (LiPF6) and applied a thermal sintering protocol.

Main Results:

  • Achieved precise control over macro-porosity and pore network formation within the PLA matrix.
  • Developed mechanically robust and ionically conductive composite SSEs after infiltration and sintering.
  • The resulting solid-state separator demonstrated an average ionic conductivity of 2.529 × 10^-5 S·cm^-1.

Conclusions:

  • The integrated FDM-sintering process offers a novel approach for fabricating SSEs with tunable properties.
  • This method enhances ion exchange, minimizes waste, and supports cost-efficient, recyclable component manufacturing for SSBs.
  • The developed SSEs show significant potential for integration into advanced solid-state battery architectures.