3D printing critical materials for rechargeable batteries: from materials, design and optimization strategies to applications

Abstract

Three-dimensional (3D) printing, one of the additive manufacturing techniques, is being broadly utilized to develop a variety of electrochemical energy storage devices (EESDs) (for instance, batteries, super-capacitors) from the nanoscale to the macroscale due to its excellent manufacturing flexibility, geometric designability, low cost, and eco-friendliness. Recent studies have reported the usage of 3D-printed critical materials for EESDs, which have demonstrated excellent electrochemical performances, including high energy densities and rate capabilities, due to the improved ion/electron transport abilities, and fast kinetics. However, the recent structural design and application of 3D printed critical materials for EESDs, especially rechargeable batteries, have been rarely summarized and discussed in the latest reported reviews. In this review, we concentrate on current progresses in 3D printing critical materials of emerging batteries. We begin by outlining the typical features of major 3D-printing methods used for fabricating EESDs, including design principles, materials selectivity, and optimization strategies. We then summarize recent progress in 3D-printed critical materials (anode, cathode, electrolyte, separator, and current collector) for secondary batteries, including conventional Li-ion (Na-ion (SIBs), K-ion (KIBs)) batteries, Li/Na/K/Zn metal batteries, Zn-air, and Ni-Fe batteries, in which the section of 3D printing precursor, the design principle of 3D structures, and the working mechanism of electrodes are discussed. In the end, we discuss the major challenges and potential applications in developing 3D-printed critical materials for rechargeable batteries. 
Keywords: additive manufacturing; 3D printing; rechargeable batteries; electrochemical energy storage devices; lithium-ion battery.





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