High-throughput production of microbatteries by a stack-punching method

Microbatteries are critical power sources for integrated circuits, wearable electronics, implantable medical devices, and microrobots. However, their practical applications have been limited by conventional bottom-up assembly methods, which suffer from low production efficiency, poor uniformity, and inferior electrochemical performance. Here we report a top-down stack-punching approach for high-throughput production of microbatteries. Through the integration of an initially anode-free design with an interpenetrating positive electrode|electrolyte fusion layer, we construct robust electrode|electrolyte interfaces to withstand the mechanical stress induced by the high-speed punching process, with a high production rate of 1800 units per hour. The resulting microbatteries are highly uniform in both physical dimensions and electrochemical performance, achieving a maximum volumetric energy density of 1306 mWh cm^-3, highly competitive among state-of-the-art microbattery technologies. As a proof-of-concept, these microbatteries are integrated with miniature sensors for continuous health monitoring and mounted onto ants and bees to potentially develop biohybrid microsystems for ecological and geological data collection. Overall, our stack-punching approach offers a promising tool for the large-scale manufacture of high-performance microbatteries, facilitating their translation into next-generation electronic devices and systems.