Solid-state batteries could possibly be extra vitality dense, safer, and sooner charging than at present’s know-how, however discovering a technique to make them commercially viable is difficult. One firm thinks 3D printing holds the reply.
In latest years, the lithium-ion batteries that energy every thing from smartphones to electrical autos have seen enormous enhancements of their security and vitality density (a measure of how a lot energy they pack in per pound). But progress is slowing, and it appears probably that we might want to swap to novel battery designs if we wish to banish the gas-powered automotive to the historical past books.
Solid-state batteries, which exchange the liquid electrolyte present in at present’s cells with a strong one, are among the most promising candidates within the close to time period. They wouldn’t solely make batteries safer by eradicating the flammable liquid electrolyte, however may additionally increase vitality density and permit sooner charging.
A lot of startups have developed promising prototypes, however figuring out how you can manufacture these sorts of batteries at scale is a significant problem. California-based startup Sakuú thinks the reply is to make use of 3D printing, which might permit them to make far more environment friendly use of area and due to this fact produce batteries with a lot increased capability than opponents.
Batteries are made up of three key parts: a constructive electrode known as an anode, a adverse electrode known as a cathode, and an electrolyte that permits ions to journey between the 2. In at present’s most superior lithium-ion batteries, the electrodes are made utilizing a manufacturing course of referred to as “roll-to-roll” manufacturing.
The supplies used to make every of the electrodes are combined right into a slurry after which coated onto an extended roll of metallic foil earlier than being dried. These lengthy rolls are then sliced up into smaller sections and stacked on high of one another with a separator between every electrode. These stacks are positioned in an enclosure that’s then stuffed with liquid electrolyte.
Even newer solid-state battery firms are proposing to make use of the identical manufacturing course of, however Sakuú is taking a very completely different strategy. It has created a 10-meter-long multi-material printer that may work with each ceramics and metals. The machine first lays down patterns of powdered materials earlier than depositing a jet of polymer binder that sticks the particles collectively. It then deposits conductive metallic on high. These layers are stacked on high of every different to provide cells.
The firm advised The Verge that the strategy permits it to stack extra layers right into a given area than standard approaches. On its web site, Sakuú claims it is because its manufacturing course of permits for thinner structural layers and a novel stacked construction. This means it may well both present one hundred pc better capability than present lithium-ion cells, or make batteries 50 p.c smaller and 40 p.c lighter.
Another engaging advantage of utilizing 3D printing is that it ought to be attainable to construct batteries in every kind of various shapes, which is tough with conventional roll-to-roll manufacturing. This may make it attainable to construct batteries into the construction of merchandise relatively than having to dedicate area for them.
This is one thing that has develop into a significant focus for the electrical automobile business, as firms try to spice up the battery capability of their autos with out including additional weight. Chinese battery maker Contemporary Amperex Technology and electrical automobile Leapmotor are engaged on methods to construct batteries into the chassis of automobiles, whereas Tesla says it has devised a brand new glue that may make its batteries load-bearing, permitting them for use as structural components.
The capacity to 3D print batteries in a wide range of shapes may turbocharge this development, however it’s more likely to be a while earlier than Sakuú’s batteries hit the highway. While it advised The Verge that every of its printers will finally be capable to churn out about 40 megawatt hours of vitality storage—the equal of 500 electrical automotive batteries—to this point it solely has a prototype of its machine, and it has not but been used to make any batteries.
If they will get their printers up and operating, although, this might present an enormous increase to efforts to improve the vary and reliability of electrical autos and push them additional into the mainstream.
Image Credit: Sakuú