image: This conceptual graphic demonstrates the core innovation of the study: a consecutive 3D printing strategy used to construct ultra-thick lithium cathodes with multidirectional ion transport pathways. Compared with traditional slurry-cast electrodes, the 3D-printed structure enables high mass loading, improved electrolyte infiltration, and enhanced mechanical integrity. These advances lead to significantly improved energy and power densities, customizable electrode designs, and record-high areal capacities—paving the way for practical high-performance lithium-ion batteries.
Credit: ©Science China Press
A team led by Prof. Zhong-Shuai Wu from the Dalian Institute of Chemical Physics, Chinese Academy of Sciences, has demonstrated a groundbreaking 3D printing method to fabricate consecutive layered lithium-ion battery cathodes with anisotropic ion transport networks. The research, recently published in Science China Chemistry, presents a new approach to overcome the long-standing trade-off between areal capacity and charge kinetics in thick electrodes.
Traditional slurry-cast thick cathodes often suffer from poor ion/electron transport and cracking, limiting their mass loading and cycling stability. To address this, the team designed B-doped NCM811 cathode inks with tailored rheological properties, enabling stable extrusion and strong interfacial adhesion during continuous layer-by-layer printing. This process resulted in ultra-thick cathodes with a mass loading of 185 mg cm-2 and a record areal capacity of 38.4 mAh cm-2, almost doubling current benchmarks.
Microscopic analysis and COMSOL simulations revealed that the printed lattice architectures facilitated multi-directional lithium-ion transport, enhancing electrochemical kinetics and active material utilization. Moreover, the cathodes maintained a high specific capacity of 208 mAh g-1 and 88% capacity retention over 150 cycles at 2 C.
In a fully 3D-printed battery pairing the cathode with a graphite anode, the team achieved a gravimetric energy density of 417 Wh kg-1 at the electrode level, demonstrating its practical application potential. The battery was able to power LED displays, small fans, and electronic devices for hours.
This work opens new avenues for customizable, high-capacity, long-lifespan energy storage systems via additive manufacturing. The authors envision the strategy’s application in flexible electronics, structural batteries, and high-power devices across aerospace, robotics, and medical fields.