What Would Battery Manufacturing Look Like on the Moon and Mars?

Maurel, Alexis; Martinez, Ana; Dornbusch, Donald A.; Huddleston, William; Seol, Myeong‐Lok; Henry, Christopher R.; Jones, Jennifer; Yelamanchi, Bharat; Chavari, Sina Bakhtar; Edmunson, Jennifer; Sreeprasad, T. S.; Cortes, Pedro; MacDonald, Eric; Sherrard, Cameroun G.

doi:10.1021/acsenergylett.2c02743

Cited by 14 publications

(15 citation statements)

References 102 publications

(133 reference statements)

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“…This is done in anticipation of an eventual water uptake during the 3D printing step and upon transfer to the glovebox for further battery assembly. Moreover, NaClO 4 is particularly relevant for space-related applications for NASA, as it could be potentially obtained on the Moon through a simple synthesis involving recycling, and due to its immediate availability on the Martian surface [7,30,31]. Table 1 summarizes the main physical properties of the electrolyte solvents and PEGDA polymer matrix that were considered.…”

Section: Gpe Composite Resins Formulationmentioning

confidence: 99%

“…However, concerns associated with the flammability of the liquid electrolyte [1] and the impact of mining scarce lithium on Earth [2] have led researchers to investigate alternatives such as sodium-ion batteries (SIBs) [3][4][5][6]. Apart from terrestrial usage, SIBs are also gathering attention in space missions for NASA, as the components and precursors for SIBs have been shown to be relatively abundant in lunar and martian surfaces [7]. In order to realize sustainable and efficient space exploration and habitats, such as those envisioned in NASA's Artemis program [8], the manufacturing at the point-of-demand sites using in-situ resource utilization is crucial.…”

Section: Introductionmentioning

confidence: 99%

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Multiprocess 3D printing of sodium-ion batteries via vat photopolymerization and direct ink writing

Martinez,

Schiaffino,

Aranzola

et al. 2023

J. Phys. Energy

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In this work, the ability to print shape-conformable batteries with multi-process additive manufacturing is reported. Vat photopolymerization (VPP) 3D printing process is employed to manufacture gel polymer electrolytes (GPEs) for sodium-ion batteries (SIBs), while direct ink writing process is used to prepare positive electrodes. The sodium-ion chemistry has proven to be an adequate substitute to lithium-ion due to the availability of resources and their potential lower production cost and enhanced safety. Three-dimensional printing technologies have the potential to revolutionize the production of shape-conformable batteries with intricate geometries that have been demonstrated to increase the specific surface area of the electrode and ion diffusion, thus leading to improved power performances. This study shows the preparation of composite UV-photocurable resins with different polymer matrix-to-liquid electrolyte ratios, designed to act as GPEs once printed via VPP. The impact of the liquid electrolyte ratio within the GPEs is thoroughly examined through a variety of electrochemical techniques. The exposure time printing parameter is optimized to ensure adequate print accuracy of the GPE. Using the optimized resin composition as material feedstock, shape-conformable 3D printed GPE exhibiting an ionic conductivity of 3.3 × 10−3 S·cm−1 at room temperature and a stability window up to 4.8 V vs. Na0/Na+ is obtained. In parallel, a composite ink loaded with Na0.44MnO2 and conductive additives is developed to 3D print via direct ink writing positive electrodes. After demonstrating the functionality of the independent 3D printed components in SIBs, the last part of this work is focused on combining the 3D printed Na0.44MnO2 electrode and the 3D printed GPE into the same battery cell to pave the way towards the manufacturing of a complete 3D printed battery thanks to different additive manufacturing processes.

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Section: Gpe Composite Resins Formulationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Multiprocess 3D printing of sodium-ion batteries via vat photopolymerization and direct ink writing

Martinez,

Schiaffino,

Aranzola

et al. 2023

J. Phys. Energy

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“…Energy supply is a critical issue in space applications as it is one of the main causes of the space systems lifespan limitation. Energy mainly comes from solar power so rechargeable Li-ion batteries (LIBs) are used for all devices from the ISS primary power system to portable communications devices, going through life support systems [12]. That is why batteries are key components that need a fast replacement in case of failure.…”

Section: Introductionmentioning

confidence: 99%

“…With this in mind, Maurel and coworkers recently introduced the possibility of 3D printing batteries with Moon or Mars resources [12]. They underlined the necessity to develop and optimize highly resolution multi-material printers to 3D manufacture batteries out of the earth.…”

Section: Introductionmentioning

confidence: 99%

3D printing of solid polymer electrolytes by fused filament fabrication: challenges towards in-space manufacturing

Bourseau,

Grugeon,

Lafont

et al. 2023

J. Phys. Energy

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A new chapter of space exploration is opening with future long-duration space missions toward the Moon and Mars. In this context, the European Space Agency (ESA) is developing out-of-the-earth manufacturing abilities, to overcome the absence of regular supplies for astronauts’ vital needs (food, health, housing, energy). Additive manufacturing is at the heart of this evolution because it allows the fabrication of tailorable and complex shapes, with a considerable ease of process. Fused Filament Fabrication (FFF), the most generalized 3D printing technique, has been integrated into the International Space Station (ISS) to produce polymer parts in microgravity. Filament deposition printing has also a key role to play in Li-ion battery (LIB) manufacturing. Indeed, it could reduce manufacturing cost & time, through one-shot printing of LIB, and improve battery performances with suitable 3D architectures. Thus, additive manufacturing via FFF of LIB in microgravity would open the way to In-Space Manufacturing (ISM) of energy storage devices. However, as liquid and volatile species are not compatible with a space station-confined environment, solvent-free 3D printing of polymer electrolytes is a necessary step to make battery printing in microgravity feasible. This is a challenging stage because of a strong opposition between the mechanical requirements of the feeding filament and electrochemical properties. Nowadays, polymer electrolyte manufacturing remains a hot topic and lots of strategies are currently being studied to overcome their poor ionic conductivity at room temperature. This work firstly gives a state of the art on the 3D printing of Li-ion batteries by FFF. Then, a summary of ionic conduction mechanisms in polymer electrolytes permits to understand the several strategies studied to enhance polymer electrolytes performances. Thanks to the confrontation with the specifications of FFF printing and the microgravity environment, polymer blends and composite electrolytes turn out to be the most suitable strategies to 3D print a lithium-ion polymer battery in microgravity.

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“…Due to this, in situ resource utilization becomes a serious consideration for the production of some or all of the oxygen and fuel on Mars using native Martian sources. − Moreover, the Martian day and night produces a different distribution of solar energy over time. An energy storage device is essential for ensuring an uninterrupted power supply. − Consequently, it is highly desirable to have a technology that can efficiently prepare oxygen and fuels on Mars while also storing energy.…”

Section: Introductionmentioning

confidence: 99%

Liquid Metal–CO₂ Battery Bridged Intermittent Energy Conversion and O₂ Production in the Martian Atmosphere

Shi

Fang

Cai

et al. 2023

ACS Sustainable Chem. Eng.

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Oxygen and fuels are requisites for outer space exploration. Herein, we use a liquid Na–Sn cathode and a Ni-based inert anode to convert CO2 into Na–Sn and oxygen in molten Na2CO3–NaCl by electrolysis, aiming to produce oxygen and store solar energy in liquid Na–Sn when the sun shines. In the same Na2CO3–NaCl electrolyte, the liquid Na–Sn serves as a negative electrode coupled with a porous FeNi positive electrode that allows the reduction of CO2 to CO in a primary cell, converting chemical energy stored in Na–Sn into electricity and CO that is a valuable fuel when the sun does not shine. This system has an overall energy efficiency of 51.0% at 100 mA cm–2. Therefore, the molten carbonate electrolysis device equipped with a liquid metal electrode could be applied for producing O2 and storing solar energy in energetic chemicals (e.g., Na–Sn, CO), which could be applied for outer space exploration such as Mars.

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What Would Battery Manufacturing Look Like on the Moon and Mars?

Cited by 14 publications

References 102 publications

Multiprocess 3D printing of sodium-ion batteries via vat photopolymerization and direct ink writing

Multiprocess 3D printing of sodium-ion batteries via vat photopolymerization and direct ink writing

3D printing of solid polymer electrolytes by fused filament fabrication: challenges towards in-space manufacturing

Liquid Metal–CO₂ Battery Bridged Intermittent Energy Conversion and O₂ Production in the Martian Atmosphere

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What Would Battery Manufacturing Look Like on the Moon and Mars?

Cited by 14 publications

References 102 publications

Multiprocess 3D printing of sodium-ion batteries via vat photopolymerization and direct ink writing

Multiprocess 3D printing of sodium-ion batteries via vat photopolymerization and direct ink writing

3D printing of solid polymer electrolytes by fused filament fabrication: challenges towards in-space manufacturing

Liquid Metal–CO2 Battery Bridged Intermittent Energy Conversion and O2 Production in the Martian Atmosphere

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Liquid Metal–CO₂ Battery Bridged Intermittent Energy Conversion and O₂ Production in the Martian Atmosphere