Considering lithium-ion battery 3D-printing via thermoplastic material extrusion and polymer powder bed fusion

In this paper, the ability to 3D print lithium-ion batteries through thermoplastic material extrusion and polymer powder bed fusion is considered. Focused on the formulation of positive electrodes composed of polypropylene, LiFePO4 as active material, and conductive additives, advantages and drawbacks of both additive manufacturing technologies, are thoroughly discussed from the electrochemical, electrical, morphological and mechanical perspectives. Based on these preliminary results, strategies to further optimize the electrochemical performances are proposed. Through a comprehensive modeling study, the enhanced electrochemical suitability at high current densities of various complex three-dimensional lithium-ion battery architectures, in comparison with classical two-dimensional planar design, is highlighted. Finally, the direct printing capability of the complete lithium-ion battery by means of multi-materials printing options processes is examined.