Lithium-Sulfur Batteries: 3D Printed Tools and Assembly Techniques for Repeatable Lab-Scale Coin Cell Manufacturing

Area of Science:

• Materials Science
• Electrochemistry
• Energy Storage

Background:

• Coin cell form factor is standard in energy storage research due to cost and efficiency.
• Lab-scale coin cell assembly requires precise manual alignment, posing challenges for data reproducibility.
• Reliable data acquisition is hindered by the lack of standardized, repeatable assembly techniques.

Purpose of the Study:

• To present a 3D-printable coin cell alignment device for reproducible lab-scale battery assembly.
• To establish a generalized workflow for consistent coin cell fabrication.
• To improve the performance and reliability of lithium-sulfur (Li-S) coin cells.

Main Methods:

• Designed and 3D-printed a coin cell alignment device.
• Developed standardized assembly techniques for lithium-sulfur (Li-S) coin cells.
• Incorporated conductive adhesive workflows for enhanced cell fabrication.

Main Results:

• Achieved up to 35% reduction in coin cell assembly times.
• Demonstrated comparable or improved functional cell yields.
• Observed enhanced electrochemical device performance, including higher average discharge capacities (up to 150 mAh/g) and improved Coulombic efficiency (up to 2.0%).

Conclusions:

• The 3D-printable alignment device and standardized workflow significantly improve the reproducibility and efficiency of Li-S coin cell assembly.
• The developed methods lead to more consistent and higher-performing electrochemical devices.
• This approach addresses key challenges in lab-scale battery research, enhancing data reliability and experimental outcomes.