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Advances in Manufacturing ›› 2025, Vol. 13 ›› Issue (2): 462-475.doi: 10.1007/s40436-024-00514-z

• • 上一篇    

Combining 3D printing of copper current collectors and electrophoretic deposition of electrode materials for structural lithium-ion batteries

Ana C. Martinez1,2, Alexis Maurel1,2, Bharat Yelamanchi3, A. Alec Talin4, Sylvie Grugeon5,6, Stéphane Panier5,7, Loic Dupont5,6, Ana Aranzola1, Eva Schiaffino1, Sreeprasad T. Sreenivasan2, Pedro Cortes3, Eric MacDonald1,8   

  1. 1. Department of Aerospace and Mechanical Engineering, The University of Texas at El Paso, El Paso, TX 79968, USA;
    2. Department of Chemistry and Biochemistry, The University of Texas at El Paso, El Paso, TX 79968, USA;
    3. Department of Civil, Environmental, and Chemical Engineering, Youngstown State University, Youngstown, OH 44555, USA;
    4. Sandia National Laboratories, Livermore, CA 94550, USA;
    5. Laboratoire de Réactivité et de Chimie des Solides, UMR CNRS 7314, Hub de l'Énergie, Université de Picardie Jules Verne, 80039 Amiens Cedex, France;
    6. RS2E, Réseau Français sur le Stockage Électrochimique de l'Énergie, FR CNRS 3459, 80039 Amiens Cedex, France;
    7. Laboratoire des Technologies Innovantes, LTI-EA 3899, Université de Picardie Jules Verne, 80025 Amiens, France;
    8. Manufacturing Demonstration Facility, Oak Ridge National Laboratory, Oak Ridge, TN 37831, USA
  • 收稿日期:2023-08-31 修回日期:2023-10-19 发布日期:2025-05-16
  • 通讯作者: Ana C. Martinez,E-mail:acmartinezm@utep.edu;Alexis Maurel,E-mail:amaurel@utep.edu E-mail:acmartinezm@utep.edu;amaurel@utep.edu;emac@utep.edu
  • 作者简介:Ana C. Martinez Received the B.S. degree in nanotechnology from the Universidad Autónoma de Querétaro (2015), the M.S. degree in materials for energy storage and conversion from a joint Erasmus+ Program (2017), and the Ph.D. degree in chemistry of materials from the Université de Picardie Jules Verne, France (2021). Ana is currently a Postdoctoral Researcher at the University of Texas at El Paso and her research interests include the synthesis of battery materials, batteries for electric vehicles and advanced characterization.
    Alexis Maurel received the B.S. degree in chemistry from the Université Toulouse III Paul Sabatier (2015), the M.S. degree in materials for energy storage and conversion from a joint Erasmus+ Program (2017), and the Ph.D. degree in chemistry of materials from the University of Picardie Jules Verne, Amiens, France (2020), for his work on lithium-ion battery 3D printing via thermoplastic material. He is currently a French Fulbright Visiting Scholar at The University of Texas at El Paso. Alexis is an expert on both energy storage and additive manufacturing. He is a member of the Electrochemical Society.
    Bharat Yelamanchi received his bachelor’s degree in mechanical engineering from Koneru Lakshmaiah college of engineering, India, M.S.E and PhD. in Industrial and Systems Engineering and Materials Science and Engineering respectively from Youngstown State University. He worked as an engineer and a researcher in the various industrial sectors for 13 years in multiple countries and is currently a faculty in Engineering department at YSU. His research interests include material development and process optimization especially in additive manufacturing, hybrid manufacturing, 3D printed multifunctional materials, composite structures, and metal-ceramic systems.
    A. Alec Talin is a Distinguished Member of Technical Staff at Sandia National Laboratories Livermore, CA 94550 USA. His research interests include nanoelectronics and nanoionics, with applications to energy-efficient and neuromorphic computing, energy storage and conversion, and national security. Talin received a Ph.D. in materials science and engineering from the University of California, Los Angeles. He is a Fellow of the American Physical Society.
    Sylvie Grugeon received the joint B.S. degree from the University of Paris VII, Paris, France, and the University of Picardie Jules Verne, (UPJV) Amiens, France, and the Ph.D. degree in material sciences from UPJV, in 1997. She is currently a Research Engineer with the Laboratoire de Réactivité et de Chimie des Solides, UPJV. Her research interests are focused on the battery field and particularly include the optimization of energy storage devices, safety, electrolyte additives, gas evolution, and 3D printing of lithium-ion batteries.
    Stéphane Panier received the Ph.D. degree from the Université des Sciences et Technologies de Lille (Lille I), France. He is currently a Professor in mechanical engineering at the Laboratoire des Technologies Innovantes, University of Picardie Jules Verne, Amiens, France, and a Visiting Professor at the Laboratoire de Réactivité et Chimie des Solides (UPJV). His research interests include additive manufacturing for a wide range of applications including energy storage and electronics.
    Loic Dupont received the Ph.D. degree in chemistry from the University of Picardie Jules Verne (UPJV), Amiens, France. He is an Expert in electronic microscopy. He is currently a Professor at UPJV as well as the Director of the microscopy platform located at the Hub de l'Énergie. His research interests include additive manufacturing of lithium-ion batteries.
    Ana Aranzola is an undergraduate research assistant at the University of Texas at El Paso majoring in mechanical engineering who was just named a Goldwater recipient during Spring 2023. Her research at UTEP focuses on additively manufacturing positive electrodes for lithium-ion batteries. Other projects she has completed at internships include 3D printed neuromorphic devices at Lawrence Livermore National Laboratory and 3D printed humidity sensors at NASA Marshall
    Eva Schiaffino is an undergraduate research assistant at the University of Texas at El Paso pursuing the Mechanical Engineering Fast-Track program. Her research focuses on the optimization of printing parameters for additive manufacturing of gelbased electrolytes as a better alternative to liquid electrolytes. Other experience includes an internship in engineering project management at Freepor t McMoran.
    Sreeprasad T. Sreenivasan received the B.S. and M.S. degrees in chemistry from Mahatma Gandhi University, India, and the Ph.D. degree in chemistry from the Indian Institute of Technology Madras, India. After completing his Ph.D. degree, he worked as a Postdoctoral Researcher at Kansas State University, USA, and the University of Toledo, USA. He is currently an Assistant Professor of chemistry at the University of Texas at El Paso. Before joining the University of Texas at El Paso, he was a Research Scientist at Clemson University and a Research Assistant Professor at the University of Toledo. His research interests include materials science and nanotechnology.
    Pedro Cortes is currently an Associate Professor with the Department of Civil/Environmental and Chemical Engineering Program as well as with the Materials Science and Engineering Program, Youngstown State University. His research interests include the area of 3-D printing, including smart and multifunctional materials, composite structures, and metal-ceramic systems. His research work has been funded through the U.S. Department of Transportation, the Department of Defense, NASA, the National Science Foundation, and the Ohio Federal Research Network. He has served twice as a Faculty Fellow of the Wright-Patterson Air Force Base.
    Eric MacDonald received the Doctoral degree in electrical and computer engineering from the University of Texas at Austin in 2002. He is a Professor of Aerospace and Mechanical Engineering and Murchison Chair with the University of Texas at El Paso and serves as the Associate Dean of Research and Graduate Studies for the College of Engineering. He held a Faculty Fellowship at the NASA’s Jet Propulsion Laboratory and U.S. Navy Research and was awarded a U.S. State Department Fulbright Fellowship in South America. His research interests include 3D printed multi-functional applications and process monitoring in additive manufacturing with instrumentation and computer vision for improved quality and yield.

Combining 3D printing of copper current collectors and electrophoretic deposition of electrode materials for structural lithium-ion batteries

Ana C. Martinez1,2, Alexis Maurel1,2, Bharat Yelamanchi3, A. Alec Talin4, Sylvie Grugeon5,6, Stéphane Panier5,7, Loic Dupont5,6, Ana Aranzola1, Eva Schiaffino1, Sreeprasad T. Sreenivasan2, Pedro Cortes3, Eric MacDonald1,8   

  1. 1. Department of Aerospace and Mechanical Engineering, The University of Texas at El Paso, El Paso, TX 79968, USA;
    2. Department of Chemistry and Biochemistry, The University of Texas at El Paso, El Paso, TX 79968, USA;
    3. Department of Civil, Environmental, and Chemical Engineering, Youngstown State University, Youngstown, OH 44555, USA;
    4. Sandia National Laboratories, Livermore, CA 94550, USA;
    5. Laboratoire de Réactivité et de Chimie des Solides, UMR CNRS 7314, Hub de l'Énergie, Université de Picardie Jules Verne, 80039 Amiens Cedex, France;
    6. RS2E, Réseau Français sur le Stockage Électrochimique de l'Énergie, FR CNRS 3459, 80039 Amiens Cedex, France;
    7. Laboratoire des Technologies Innovantes, LTI-EA 3899, Université de Picardie Jules Verne, 80025 Amiens, France;
    8. Manufacturing Demonstration Facility, Oak Ridge National Laboratory, Oak Ridge, TN 37831, USA
  • Received:2023-08-31 Revised:2023-10-19 Published:2025-05-16
  • Contact: Ana C. Martinez,E-mail:acmartinezm@utep.edu;Alexis Maurel,E-mail:amaurel@utep.edu E-mail:acmartinezm@utep.edu;amaurel@utep.edu;emac@utep.edu

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摘要： Serving as a proof of concept, additive manufacturing and electrophoretic deposition are leveraged in this work to enable structural lithium-ion batteries with load-bearing and energy storage dual functionality. The preparation steps of a complex 3D printed copper current collector, involving the formulation of a photocurable resin formulation, as well as the vat photopolymerization process followed by a precursors-based solution soaking step and thermal post-processing are presented. Compression and microhardness testing onto the resulting 3D printed copper current collector are shown to demonstrate adequate mechanical performance. Electrophoretic deposition of graphite as a negative electrode active material and other additives was then performed onto the 3D printed copper collector, with the intention to demonstrate energy storage functionality. Half-cell electrochemical cycling of the 3D multi-material current collector/negative electrode versus lithium metal finally demonstrates that structural battery components can be successfully obtained through this approach.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00514-z

关键词: Copper manufacturing, 3D printing, Structural batteries, Vat photopolymerization, Electrophoretic deposition

Abstract: Serving as a proof of concept, additive manufacturing and electrophoretic deposition are leveraged in this work to enable structural lithium-ion batteries with load-bearing and energy storage dual functionality. The preparation steps of a complex 3D printed copper current collector, involving the formulation of a photocurable resin formulation, as well as the vat photopolymerization process followed by a precursors-based solution soaking step and thermal post-processing are presented. Compression and microhardness testing onto the resulting 3D printed copper current collector are shown to demonstrate adequate mechanical performance. Electrophoretic deposition of graphite as a negative electrode active material and other additives was then performed onto the 3D printed copper collector, with the intention to demonstrate energy storage functionality. Half-cell electrochemical cycling of the 3D multi-material current collector/negative electrode versus lithium metal finally demonstrates that structural battery components can be successfully obtained through this approach.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00514-z

Key words: Copper manufacturing, 3D printing, Structural batteries, Vat photopolymerization, Electrophoretic deposition

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