"Exploring the Potential of 3D-Printed Solid-State Batteries"

The search for a better rechargeable battery is on, with the potential for more power, safety, speed, and lifespan. Researchers and private companies are racing to develop a battery that could replace the ubiquitous lithium-ion battery. And one company, in particular, is pushing the boundaries even further by exploring the potential of 3D printing batteries. By doing so, they aim to change our perception of what a battery can look like and how it can be used in various applications.

To understand how a battery works, it's important to know that it converts chemical energy into electrical energy. Essentially, a battery consists of three main components: a positive end or cathode, a negative end or anode, and an electrolyte that connects the two. The cathode and anode are typically made of different materials, such as metals, and the electrolyte is a substance that can conduct ions. When the cathode and anode are connected through a wire or other conductive material, a chemical reaction occurs within the battery that generates an electrical current. This current can then be used to power various devices, from flashlights to electric cars.

A battery converts chemical energy into electricity, with a positive end or cathode, and a negative end or anode, connected by an electrolyte. Lithium ion batteries are successful versions of this, but there is room for improvement in the design, specifically the electrolyte and anode. Startups are experimenting with solid-state batteries, using stable, non-flammable electrolytes made from materials like ceramics, glasses, and polymers. They are also searching for more powerful anode materials, with lithium metal as a strong candidate. However, lithium metal tends to form dendrites that can short the battery, but using a solid electrolyte could improve this. One California-based company, Sakuu, is designing solid-state batteries with lithium metal anodes and plans to 3D print them, which could improve the overall capacity of the battery. This is how Sakuu hopes to outcompete other solid-state startups and lithium ion makers who are sticking with roll-to-roll manufacturing.

The idea of 3D printed batteries is a promising innovation, but there are still many hurdles to overcome before it becomes a reality. Sakuu has created a prototype for 3D printed solid-state batteries in their lab, but they have yet to fully print a battery using their technology. The prototype is being tested, and Sakuu is working on making the best battery possible using this manufacturing process. The 3D printer prototype is not ready to be revealed to the public, as there is proprietary information involved. Sakuu hopes to eventually produce 40 megawatt hours of energy storage annually using their printers, which is the equivalent of 500 electric car batteries per year. The 3D printing process can create batteries in different shapes, which is not possible using roll-to-roll technology. This means that batteries could become an integral part of a product, rather than being designed around a battery. However, introducing a new manufacturing process to an established industry is always challenging. While startups like Sakuu are testing their first generation products, lithium ion batteries are still getting cheaper and more powerful. Sakuu is currently building its first factory and hopes to get sample batteries out to clients in 2023. The need for more advanced batteries is growing, especially for electric vehicles and large-scale energy storage, but newcomers must create batteries that are perfect and can stand the test of time