3D Printed Lithium-Metal Full Batteries Based on a High-Performance Three-Dimensional Anode Current Collector

3D Printed Flexible Zinc-Ion Battery for Real-Time Health Monitoring Devices

The growing need for multifunctional wearable electronics for mobile applications has triggered the demand for flexible and reliable energy storage devices. 3D printing technology has emerged as a promising and attractive method for manufacturing these devices. This study presents the design and fabrication of a flexible quasi-solid-state Zn-ion battery using the direct-writing 3D printing technique. A conductive silver paste with high conductivity was printed onto a PET substrate to serve as the current collector. The cathode was fabricated from carbon-coated MnO2 nanorods produced using hydrothermal methods, while the anode consisted of commercial zinc powder. The cathode and anode slurries exhibiting excellent viscoelasticity were 3D printed on the current collector. To complete the flexible quasi-solid-state zinc-ion battery, a PVA gel electrolyte was printed onto the PET substrate. This battery delivered an initial capacity of 267.3 mAh g-1 and maintained a capacity of 189.7 mAh g-1 after 500 cycles at a current density of 0.2 A g-1. Furthermore, the 3D printed battery successfully powered a portable human heart rate sensor, showcasing the potential of 3D printing technology as an environmentally friendly, cost-effective, and scalable solution for wearable energy storage devices.

Novel Lithiophilic Silver Selenide Nanocrystals within Porous Carbon Microsphere: Tailoring Pore Structures for Enhanced Lithium Metal Battery Anodes

To enable the practical use of a lithium metal anode, the rational design of three-dimensional (3D) host materials is considered as a promising approach to mitigate lithium dendrite formation and accommodate substantial volume fluctuations. Herein, we first design a 3D conductive host material comprised of Ag2Se nanocrystals encapsulated within closed pore structured porous carbon microspheres. The homogeneous distribution of the AgLi alloy and Li2Se phases, generated through the consecutive conversion and alloying reaction of the Ag2Se phase, enables the developed host materials to exhibit rapid lithium deposition kinetics. Additionally, the inner void structures with encapsulated lithiophilic nanocrystals promote primary deposition within the carbon framework without dendrite growth. Consequently, optimized pore structure as well as position of lithiophilic nanocrystals in carbon microsphere are rationally tailored for stable plating/stripping behaviors of lithium with high Coulombic efficiency and stable voltage profiles. Paired with the LiNi0.8Co0.1Mn0.1O2 cathode, the assembled full cell demonstrates outstanding cycling stability and impressive high-rate performance, highlighting its potential for practical applications. Moreover, to explore how different pore structures influence the stability of the Li metal host, Ag2Se@C hosts with various pore structures (including open pore structures and densely structured configurations without inner voids) are also fabricated and compared with the developed host material.

Phosphorized 3D Current Collector for High-Energy Anode-Free Lithium Metal Batteries

The anode-free lithium metal battery (AF-LMB) demonstrates the emerging battery chemistry, exhibiting higher energy density than the existing lithium-ion battery and conventional LMB empirically. A systematic step-by-step while bottom-up calculation system is first developed to quantitatively depict the energy gap from theory to practice. The attainable high energy of AF-LMB necessitates a homogeneous Li+ flux on the anode side to achieve an improved Li reversibility against inventory loss. On such basis, a lithiophilic Cu3P-decorated 3D copper foil to promote dendrite-free lithium deposition is further reported. The phosphorized surface of high affinity toward Li+ incorporating the nanostructure of abundant nucleation sites synergistically regulates the Li nucleation/growth behavior, extending the cycling lifespan of high-loading AF-LMBs. The processed foil featuring lightweight and ultrathin merits further increases the energy density, both gravimetrically and volumetrically. This study provides a novel scheme for simultaneously realizing the uniform deposition of lithium and increasing the energy density of future AF-LMBs.

Constructing Three-Dimensional Architectures to Design Advanced Copper-Based Current Collector Materials for Alkali Metal Batteries: From Nanoscale to Microscale

Alkali metals (Li, Na, and K) are deemed as the ideal anode materials for next-generation high-energy-density batteries because of their high theoretical specific capacity and low redox potentials. However, alkali metal anodes (AMAs) still face some challenges hindering their further applications, including uncontrollable dendrite growth and unstable solid electrolyte interphase during cycling, resulting in low Coulombic efficiency and inferior cycling performance. In this regard, designing 3D current collectors as hosts for AMAs is one of the most effective ways to address the above-mentioned problems, because their sufficient space could accommodate AMAs' volume expansion, and their high specific surface area could lower the local current density, leading to the uniform deposition of alkali metals. Herein, we review recent progress on the application of 3D Cu-based current collectors in stable and dendrite-free AMAs. The most widely used modification methods of 3D Cu-based current collectors are summarized. Furthermore, the relationships among methods of modification, structure and composition, and the electrochemical properties of AMAs using Cu-based current collectors, are systematically discussed. Finally, the challenges and prospects for future study and applications of Cu-based current collectors in high-performance alkali metal batteries are proposed.

The status and challenging perspectives of 3D-printed micro-batteries

In the era of the Internet of Things and wearable electronics, 3D-printed micro-batteries with miniaturization, aesthetic diversity and high aspect ratio, have emerged as a recent innovation that solves the problems of limited design diversity, poor flexibility and low mass loading of materials associated with traditional power sources restricted by the slurry-casting method. Thus, a comprehensive understanding of the rational design of 3D-printed materials, inks, methods, configurations and systems is critical to optimize the electrochemical performance of customizable 3D-printed micro-batteries. In this review, we offer a key overview and systematic discussion on 3D-printed micro-batteries, emphasizing the close relationship between printable materials and printing technology, as well as the reasonable design of inks. Initially, we compare the distinct characteristics of various printing technologies, and subsequently emphatically expound the printable components of micro-batteries and general approaches to prepare printable inks. After that, we focus on the outstanding role played by 3D printing design in the device architecture, battery configuration, performance improvement, and system integration. Finally, the future challenges and perspectives concerning high-performance 3D-printed micro-batteries are adequately highlighted and discussed. This comprehensive discussion aims at providing a blueprint for the design and construction of next-generation 3D-printed micro-batteries.

Copper Current Collector: The Cornerstones of Practical Lithium Metal and Anode-Free Batteries

Comparing with the commercial Li-ion batteries, Li metal secondary batteries (LMB) exhibit unparalleled energy density. However, many issues have hindered the practical application. As an element in lithium metal and anode-free batteries, the role of current collector is critical. Comparing with the cathode current collector, more requirements have been imposed on anode current collector as the anode side is usually the starting point of thermal runaway and many other risks, additionally, the anode in Li metal battery very likely determines the cycling life of full cell. In the review, we first give a systematic introduction of copper current collector and the related issues and challenges, and then we summarize the main approaches that have been mentioned in the research, including Cu current collector with 3D architecture, lithophilic modification of the current collector, artificial SEI layer construction on Cu current collector and carbon or polymer decoration of Cu current collector. Finally, we give a prospective comment of the future development in this field.

Covalent Organic Framework Fiber-Constructed Artificial Solid Electrolyte Interphase Layer: Facilitated Uniform Deposition of Li+ and Encapsulated Li Dendrite

Due to ultrahigh theoretical capacity and ultralow redox poteneial, lithium metal is considered as a promising anode material. However, uneven lithium deposition, uncontrollable lithium dendrite formation, and fragile solid electrolyte interphase (SEI) lead to low lithium utilization, rapid capacity decay, and poor cycle performance. Herein, a robust artificial SEI film by coating the lithium surface with fibrous covalent organic framework (Fib-COF) was constructed, which effectively prevented dendrite penetration and battery short-circuits. Experimental results demonstrated that the Fib-COF-decorated batteries showcased higher Coulombic efficiency (CE), extended cycling stability, and superior electrolyte compatibility. The strong affinity of the carbonyl group in Fib-COF towards Li+ contributes to facilitating the Li+ uniform transfer and nucleation. In situ optical microscopy dynamically revealed the formation process of dendrite-free interphase under the function of Fib-COF layer. As a result, the modified Li anode demonstrated remarkable cycle stability for more than 650 h at 20 mA cm-2 and 5 mAh cm-2 in ether-based electrolyte and 1000 h at 0.5 mA cm-2 and 0.5 mAh cm-2 in carbonate-based electrolyte. The dendrite-free Fib-COF@Li electrodes endowed higher specific capacities of 650 mAh g-1 for Fib-COF@Li|S full cell after 250 cycles and 120 mAh g-1 for Fib-COF @Li|LiFePO4 full cells after 300 cycles.

3D printing of hierarchically micro/nanostructured electrodes for high-performance rechargeable batteries

3D printing, also known as additive manufacturing, is capable of fabricating 3D hierarchical micro/nanostructures by depositing a layer-upon-layer of precursor materials and solvent-based inks under the assistance of computer-aided design (CAD) files. 3D printing has been employed to construct 3D hierarchically micro/nanostructured electrodes for rechargeable batteries, endowing them with high specific surface areas, short ion transport lengths, and high mass loading. This review summarizes the advantages and limitations of various 3D printing methods and presents the recent developments of 3D-printed electrodes in rechargeable batteries, such as lithium-ion batteries, sodium-ion batteries, and lithium-sulfur batteries. Furthermore, the challenges and perspectives of the 3D printing technique for electrodes and rechargeable batteries are put forward. This review will provide new insight into the 3D printing of hierarchically micro/nanostructured electrodes in rechargeable batteries and promote the development of 3D printed electrodes and batteries in the future.

Advanced Material Engineering to Tailor Nucleation and Growth towards Uniform Deposition for Anode-Less Lithium Metal Batteries

Anode-less lithium metal batteries (ALMBs), whether employing liquid or solid electrolytes, have significant advantages such as lowered costs and increased energy density over lithium metal batteries (LMBs). Among many issues, dendrite growth and non-uniform plating which results in poor coulombic efficiency are the key issues that viciously decrease the longevity of the ALMBs. As a result, lowering the nucleation barrier and facilitating lithium growth towards uniform plating is even more critical in ALMBs. While extensive reviews have focused to describe strategies to achieve high performance in LMBs and ALMBs, this review focuses on strategies designed to directly facilitate nucleation and growth of dendrite-free ALMBs. The review begins with a discussion of the primary components of ALMBs, followed by a brief theoretical analysis of the nucleation and growth mechanism for ALMBs. The review then emphasizes key examples for each strategy in order to highlight the mechanisms and rationale that facilitate lithium plating. By comparing the structure and mechanisms of key materials, the review discusses their benefits and drawbacks. Finally, major trends and key findings are summarized, as well as an outlook on the scientific and economic gaps in ALMBs.

Porous Metal Current Collectors for Alkali Metal Batteries

Alkali metals (i.e., Li, Na, and K) are promising anode materials for next-generation high-energy-density batteries due to their superior theoretical specific capacities and low electrochemical potentials. However, the uneven current and ion distribution on the anode surface probably induces undesirable dendrite growth, which leads to significant safety hazards and severely hinders the commercialization of alkali metal anodes. A smart and versatile strategy that can accommodate alkali metals into porous metal current collectors (PMCCs) has been well established to resolve the issues as well as to promote the practical applications of alkali metal anodes. Moreover, the proposal of PMCCs can meet the requirement of the dendrite-free battery fabrication industry, while the electrode material loading exactly needs the metal current collector component as well. Here, a systematic survey on advanced PMCCs for Li, Na, and K alkali metal anodes is presented, including their development timeline, categories, fabrication methods, and working mechanism. On this basis, some significant methodology advances to control pore structure, surface area, surface wettability, and mechanical properties are systematically summarized. Further, the existing issues and the development prospects of PMCCs to improve anode performance in alkali metal batteries are discussed.

Pomegranate-Inspired Graphene Parcel Enables High-Performance Dendrite-Free Lithium Metal Anodes

Uncontrolled lithium dendrites seriously hinder the commercialization of lithium metal batteries in comparison to the durable lithium-ion batteries. Herein, inspired by squashy pomegranate structure, a novel loading strategy of metallic lithium (Li) is introduced to construct dendrite-free Li metal anodes through porous reduced graphene oxide/Au (PRGO/Au) composite microrods (MRs) as unique storage parcels. The abundant internal voids and robust host structure are capable of achieving high mass loading of Li metal and effectively alleviating the conceivable volume change during cycling, accompanied by the preferential selective plating/stripping of Li inside the graphene-based MRs with the embedded Au nanonuclei. As a result, the obtained PRGO/Au-Li anodes deliver a long-lifespan stable cycling up to 600 h with a high specific capacity of ≈2140 mA h g^-1 and voltage hysteresis as low as 20 mV in the absence of dendrites. The assembled full cells exhibit excellent rate capability and cycling stability. This work provides an alternative strategy to construct advanced high-energy-density lithium batteries via the unique 1D bioinspired graphene-based packaging strategy.

Smart Manufacturing Processes of Low-Tortuous Structures for High-Rate Electrochemical Energy Storage Devices

To maximize the performance of energy storage systems more effectively, modern batteries/supercapacitors not only require high energy density but also need to be fully recharged within a short time or capable of high-power discharge for electric vehicles and power applications. Thus, how to improve the rate capability of batteries or supercapacitors is a very important direction of research and engineering. Making low-tortuous structures is an efficient means to boost power density without replacing materials or sacrificing energy density. In recent years, numerous manufacturing methods have been developed to prepare low-tortuous configurations for fast ion transportation, leading to impressive high-rate electrochemical performance. This review paper summarizes several smart manufacturing processes for making well-aligned 3D microstructures for batteries and supercapacitors. These techniques can also be adopted in other advanced fields that require sophisticated structural control to achieve superior properties.

Composites Additive Manufacturing for Space Applications: A Review

The assembly of 3D printed composites has a wide range of applications for ground preparation of space systems, in-orbit manufacturing, or even in-situ resource utilisation on planetary surfaces. The recent developments in composites additive manufacturing (AM) technologies include indoor experimentation on the International Space Station, and technological demonstrations will follow using satellite platforms on the Low Earth Orbits (LEOs) in the next few years. This review paper surveys AM technologies for varied off-Earth purposes where components or tools made of composite materials become necessary: mechanical, electrical, electrochemical and medical applications. Recommendations are also made on how to utilize AM technologies developed for ground applications, both commercial-off-the-shelf (COTS) and laboratory-based, to reduce development costs and promote sustainability.

One-step side-by-side 3D printing constructing linear full batteries

A one-step side-by-side 3D printing method is proposed to construct linear lithium-, sodium-, and zinc-ion full batteries with high electrochemical performance. The inks of the battery components present shear thinning characteristics and can be printed on different substrates. This approach to design high performance linear full batteries is a general strategy.

Compact 3D Metal Collectors Enabled by Roll-to-Roll Nanoimprinting for Improving Capacitive Energy Storage

Reducing the contact resistance between active materials and current collectors is of engineering importance for improving capacitive energy storage. 3D current collectors have shown extraordinary promise for reducing the contact resistance, however, there is a major obstacle of being bulky or inefficient fabrication before they become viable in practice. Here a roll-to-roll nanoimprinting method is demonstrated to deform flat aluminum foils into 3D current collectors with hierarchical microstructures by combining soft matter-enhanced plastic deformation and template-confined local surface nanocracks. The generated 3D current collectors are inserted by and interlocked with active electrode materials such as activated carbon, decreasing the contact resistance by at least one order of magnitude and quadrupling the specific capacitance at high current density of 30 A g^-1 for commercial-level mass loading of 5 mg cm^-2 . The 3D current collectors are so compact that they have a low volume percentage of 7.8% in the entire electrode film, resulting in energy and power density of 29.1 Wh L^-1 and 12.8 kW L^-1 , respectively, for stack cells in organic electrolyte. Furthermore, roll-to-roll nanoimprinting of metal microstructures is low-cost, high-throughput, and can be extended to other systems that involve the microstructured metal interface, such as batteries and thermal management.

3D Printing for Solid-State Energy Storage

Ever-growing demand to develop satisfactory electrochemical devices has driven cutting-edge research in designing and manufacturing reliable solid-state electrochemical energy storage devices (EESDs). 3D printing, a precise and programmable layer-by-layer manufacturing technology, has drawn substantial attention to build advanced solid-state EESDs and unveil intrinsic charge storage mechanisms. It provides brand-new opportunities as well as some challenges in the field of solid-state energy storage. This review focuses on the topic of 3D printing for solid-state energy storage, which bridges the gap between advanced manufacturing and future EESDs. It starts from a brief introduction followed by an emphasis on 3D printing principles, where basic features of 3D printing and key issues for solid-state energy storage are both reviewed. Recent advances in 3D printed solid-state EESDs including solid-state batteries and solid-state supercapacitors are then summarized. Conclusions and perspectives are also provided regarding the further development of 3D printed solid-state EESDs. It can be expected that advanced 3D printing will significantly promote future evolution of solid-state EESDs.

Uniform Deposition of Li-Metal Anodes Guided by 3D Current Collectors with In Situ Modification of the Lithiophilic Matrix

The lithium (Li)-metal anode is deemed as the "holy gray" of the next-generation Li-metal system because of its high theoretical specific capacity, minimal energy density, and lowest standard electrode potential. Nevertheless, its commercial application has been limited by the large volume variation during charge and discharge, the unstable interface between the Li metal and electrolyte, and uneven deposition of Li. Herein, we present a 3D host (Cu) with lithiophilic matrix (CuO and SnO₂) in situ modification via a facile ammonia oxidation method to serve as a current collector for the Li-metal anode. The 3D Cu host embellished by CuO and SnO₂ is abbreviated as 3D CSCC. By increasing interfacial activity, lowering the nucleation barrier, and accommodating changes in volume of the Li metal, the 3D CSCC electrode effectively demonstrates a homogeneous and dendrite-free deposition morphology with an excellent cycling performance up to 3000 h at a 1.0 mA cm^-2 current density. Additionally, the full cells paired with Li@3D CSCC anodes and LiCoO₂ cathodes show good capacity retention performance at 0.2 C.

Integrated Battery-Capacitor Electrodes: Pyridinic N-Doped Porous Carbon-Coated Abundant Oxygen Vacancy Mn-Ni-Layered Double Oxide for Hybrid Supercapacitors

Integrating the battery behavior and supercapacitor behavior in a single electrode to obtain better electrochemical performance has been widely researched. However, there is still a lack of research studies on an integrated battery-capacitor supercapacitor electrode (BatCap electrode). In this work, an integrated BatCap electrode porous carbon-coated Mn-Ni-layered double oxide (Mn-Ni LDO-C) was fabricated successfully using controllable heat treatment of polypyrrole-precoated Mn-Ni-layered double hydroxide (Mn-Ni LDH@PPy). This Mn-Ni LDO-C electrode was grown on Ni foam directly and possessed a hierarchical structure that consisted of a pyridinic N (N-6)-doped porous carbon shell and a Mn-Ni LDO core within abundant oxygen vacancies. Benefiting from the synergistic effect of N-6-doped porous carbon and increased oxygen vacancies, Mn-Ni LDO-C exhibited excellent electrochemical performance. The capacity of Mn-Ni LDO-C reached 2.36 C cm^-2 (1478.1 C g^-1) at 1 mA cm^-2 and remained at 92.1% of the initial capacity after 5000 cycles at a current density of 20 mA cm^-2. The aqueous battery-supercapacitor hybrid device Mn-Ni LDO-C//active carbon (Mn-Ni LDO-C//AC) also presented superior cycle stability: it retained 85.3% of the original capacity after 5000 cycles at 2 A g^-1. Meanwhile, Mn-Ni LDO-C//AC could work normally under a wider potential window (2.0 V), so that the device held the highest energy density of 78.2 Wh kg^-1 at a power density of 499.7 W kg^-1 and retained 39.1 Wh kg^-1 at the highest power density of 31.3 kW kg^-1. Two Mn-Ni LDO-C//AC devices connected in series could light a light-emitting diode (LED) bulb easily and keep the LED brightly illuminated for more than 10 min. In general, this work synthesized an integrated BatCap electrode Mn-Ni LDO-C; the integrated electrode exhibited high electrochemical performance, thus has a promising application prospect in the field of energy storage.