Researchers created this tiny Lithium-ion battery using the FFF (Fused Filament Fabrication) method in a single print by exchanging the filament at specific layer heights, and then vacuum filled with an electrolyte. (Image credit: Duke/Texas State University)
Researchers from Duke and Texas State University have designed a way to 3D print Lithium-ion batteries in nearly any shape imaginable. One of the challenges manufacturers face today, is that mobile devices, electric vehicles, and wearables (among a host of others) are typically designed around the shape (square or cylindrical) and size of said batteries, which tends to waste space and design options.
A new paper from the research team has developed a process to 3D print custom lithium-ion batteries with readily available technology- in this case; a FFF (Fused Filament Fabrication) 3D printer and a new type of conductive PLA filament.
Traditionally, the PLA polymer used in this type of fabrication process are not ionic conductors (current transported via ions), and therefore cannot replicate the electric current tech found in lithium-ion batteries.
To overcome this issue, the researchers increased the ion conductivity of the PLA polymer by infusing it with an electrolyte solution. 3D printing the battery is done in a single print by exchanging the filament at specific layer heights, which is then vacuum filled with the electrolyte solution. They also increased the battery’s conductivity by injecting graphene in the form of carbon nanotubes into the anode and cathode.
The research team demonstrated their process by 3D printing LCD sunglasses and bangle LED bracelet. (Image credit: Duke/Texas State University)
To demonstrate the 3D printed battery’s potential, the team created an LED bangle bracelet and a pair of LCD sunglasses with integrated lithium-ion batteries. It should be noted that this new fabrication process is still in its early stages, and the researchers noted- “The capacity of the first-generation 3D-printed battery is about two orders of magnitude lower than that of commercial batteries, which is too low for practical use.” That said, they do have some ideas on how to boost the batteries performance, including using metal-infused paste instead of electrolyte-injected PLA polymer.
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