Toward High Resolution 3D Printing of Shape-Conformable Batteries via Vat Photopolymerization: Review and Perspective

High-resolution additive manufacturing offers access to the production of intricate architectures with small features that can revolutionize the fabrication of next-generation batteries. Relegated to two-dimensional sheets, commercial lithium-ion batteries consist of stacked leaflets, which are manufactured in restricted stacked or rolled geometries. By leveraging the most recent advancements of vat photopolymerization (VPP), the next-generation of shape-conformable three-dimensional batteries can be co-designed with known application requirements and provide enhanced safety and power performance based on reduced weight and dead volume. Herein, an overview of the state of the art with perspectives towards the development of electroactive photo-polymerizable resins for the direct fabrication of complete multi-material three-dimensional batteries is presented. Different approaches are described, including the formulation of composite resin through the introduction of solid electroactive particles, soluble components or metal precursors. Finally, the impact of the thermal post-processing steps on the resulting electrochemical properties of the VPP printed battery component or device is thoroughly discussed. This study paves the way towards the manufacturing of a complete high-resolution shape conformable 3D battery via VPP with enhanced power density.

Automated summary

High-resolution additive manufacturing enables the production of intricate structures that could revolutionize the fabrication of next-generation batteries. By utilizing vat photopolymerization technology, shape-conformable three-dimensional batteries with improved safety and power performance can be co-designed for specific applications, reducing weight and dead volume. Different approaches such as introducing solid electroactive particles or metal precursors are discussed, along with the impact of thermal post-processing on the electrochemical properties of VPP printed battery components.