Towards 3D-Printed All-Solid-State Batteries: A Rheological Optimization of Anode, Cathode, and Electrolyte Materials

The development of all-solid-state batteries (ASSB) represents a significant advancement in energy
storage, offering increased safety, higher energy density, and improved lifespan compared to
conventional liquid electrolyte batteries [1]. However, implementation challenges persist, notably
electrode-electrolyte interfaces which remain a challenge in terms of reactivity and conductivity [2].
Recent advancements in additive manufacturing, particularly 3D printing technologies, have opened
new avenues for fabricating complex battery architectures with high precision [3]. In this project, we
utilize powder bed 3D printing equipped with a multi-material head capable of simultaneously
depositing multiple materials. This enables the creation of interfaces with composition gradients
between electrodes and solid-electrolyte within a single battery structure and facilitates one-step battery
fabrication. This capability has the potential to minimize interfacial resistance and enhance battery
performance [4]. However, the practical implementation of 3D printing in battery manufacturing faces
several challenges, including optimizing material properties to ensure uniformity and enhance the
performance [4]. In this study, our focus is on developing anode, cathode, and electrolyte materials. We
employ spray-drying technique for synthesizing these materials, and subsequently optimize their
rheological properties for use in powder bed 3D printing technology. The flowability is characterized
by using a Granudrum™️ to determine avalanche angle and cohesive index. We then analyze their
deposition using die-pressing technique.
REFERENCES
[1] J.B. Goodenough, Y. Kim, Challenges for rechargeable Li batteries, Chemistry of Materials 22 (2010) 587–
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[2] Y. Pang, J. Pan, J. Yang, S. Zheng, C. Wang, Electrolyte/Electrode Interfaces in All-Solid-State Lithium
Batteries: A Review, Electrochemical Energy Reviews 4 (2021) 169–193. https://doi.org/10.1007/s41918-020-
00092-1.
[3] K. Xu, Nonaqueous liquid electrolytes for lithium-based rechargeable batteries, Chem Rev 104 (2004) 4303–
4417. https://doi.org/10.1021/cr030203g.
[4] Y. Liang, H. Liu, G. Wang, C. Wang, Y. Ni, C.W. Nan, L.Z. Fan, Challenges, interface engineering, and
processing strategies toward practical sulfide-based all-solid-state lithium batteries, InfoMat 4 (2022).
https://doi.org/10.1002/inf2.12292.