A new printable electrolyte could enable batteries to be manufactured in almost any shape without sacrificing performance.
Researchers from the University of Texas at El Paso (UTEP) have created a 3D printing technique that allows battery electrolytes to be printed in almost any shape while maintaining performance comparable to traditional liquid electrolytes. The innovation might lead to batteries that could be incorporated into wearables, medical devices, aircraft parts, and other small devices.
The key lies in the electrolyte, which transports charged particles between the two ends of the battery. In order to address the problem of traditional liquid electrolytes, which need a rigid housing and can leak, researchers have invented a printable gel polymer electrolyte by mixing a light-curable resin with a lithium-based liquid electrolyte. It is produced with the help of a vat photopolymerisation technique that solidifies the material layer by layer through illumination.
Tests demonstrated that the printed electrolyte reached the ionic conductivity of up to 3.4 × 10⁻³ siemens per centimetre, comparable to traditional liquid electrolytes. The best printability and performance were achieved with a resin-to-electrolyte ratio of 1:4. Moreover, the material could be printed under standard laboratory conditions, without requiring a sealed or oxygen-free environment.
The versatility of the technique was shown by printing various designs, such as planar discs, open-cell honeycomb lattice, and a solid cube with a side of 0.4 inches.
“We are showing that you can print a high-performing electrolyte battery component with any shape and place it almost anywhere you want. That changes what designers are able to imagine,” said Alexis Maurel, the study’s lead researcher.
The researchers now plan to optimise the electrolyte formulations and use the printed material to develop complete battery cells.
