Photocentric
Optimising formulations for 3D printed solid-state batteries
The challenge
Batteries store and discharge energy through the movement of positive ions and negative electrons. They also contain an electrolyte that facilitates the movement of positive ions to create an electrical current.
Conventional batteries contain a liquid electrolyte, which is often flammable and hazardous. Solid-state batteries contain a solid electrolyte, which is significantly safer, however, they are often expensive and have design limitations.
To develop customisable, conformable, and safe batteries for use in novel applications, we collaborated with Photocentric to test whether additive manufacturing (3D printing) techniques could be applied to solid-state battery technology. To enable this, we needed to develop a functional 3D printable ink formulation that could carry an electrical charge.
![](https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/3D-printing-stock_image.jpg?w=1920&h=1080&q=60&fm=jpg&fit=crop&dm=1648812338&s=cfe154d35b9fa10793a2af243586a719 1920w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/3D-printing-stock_image.jpg?w=1120&h=630&q=60&fm=jpg&fit=crop&dm=1648812338&s=f0f791688bb0df0f841d1e94572316d5 1120w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/3D-printing-stock_image.jpg?w=2240&h=1260&q=45&fm=jpg&fit=crop&dm=1648812338&s=ca8a4afcb31876f1371b1eec2d3af31d 2240w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/3D-printing-stock_image.jpg?w=800&h=450&q=60&fm=jpg&fit=crop&dm=1648812338&s=9bb160d6b1a0d3f4526a4b6c45d06453 800w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/3D-printing-stock_image.jpg?w=1600&h=900&q=45&fm=jpg&fit=crop&dm=1648812338&s=d46f45ebc7053c00a795018594e61a27 1600w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/3D-printing-stock_image.jpg?w=480&h=270&q=60&fm=jpg&fit=crop&dm=1648812338&s=cf75a11f7c796dc614d86bb759182781 480w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/3D-printing-stock_image.jpg?w=960&h=540&q=45&fm=jpg&fit=crop&dm=1648812338&s=8b35df9cb53990764a658c03e01baf91 960w)
“With CPI’s help, we now have a solid proof-of-concept that we’ve been able to move forward in the development process to higher TRL levels. CPI aided in delivering results and knowledge with a reduced capital investment, allowing us to to achieve our goal in a shorter time span.”
![Robert Young Robert Young](https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/robert-young.jpg?w=100&h=100&q=60&fm=jpg&fit=crop&dm=1653475045&s=64c04b14cae2fa4cdf39b92d3339292c)
How CPI helped
- Applied expertise and capability in ink formulation and extrusion
- Explored a selection of materials that could be UV curable, and therefore 3D printable, using Photo-DSC
- Applied high throughput automation capabilities to explore a wide range of formulations
- Tested battery functionality using Electrical Impedance Spectroscopy (EIS) to efficiently measure ionic conductivity
![](https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/3d-printing-pod-2.jpg?w=1920&h=1080&q=60&fm=jpg&fit=crop&dm=1607595553&s=02e6a7fced0d41a1c858fed4db8412ba 1920w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/3d-printing-pod-2.jpg?w=1120&h=630&q=60&fm=jpg&fit=crop&dm=1607595553&s=209efe6a055dc32570ec1831f14e25cd 1120w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/3d-printing-pod-2.jpg?w=800&h=450&q=60&fm=jpg&fit=crop&dm=1607595553&s=b94683762a99a4bdf62d4b85d694be82 800w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/3d-printing-pod-2.jpg?w=1600&h=900&q=45&fm=jpg&fit=crop&dm=1607595553&s=ebfba7fd1c1ab13605e349513fe7b2c5 1600w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/3d-printing-pod-2.jpg?w=480&h=270&q=60&fm=jpg&fit=crop&dm=1607595553&s=0508d0d3b34a1c92060c7a2a0d95e09a 480w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/3d-printing-pod-2.jpg?w=960&h=540&q=45&fm=jpg&fit=crop&dm=1607595553&s=27ccdca2bee90061a40f483a6616108c 960w)
Achievements
- Overcame common UV curing challenges when using light blocking materials to develop a UV curable printable resin
- Developed and optimised a polymer electrolyte formulation into a printable resin
- Printed the cathode materials using a functional binder via a Fused Deposition Modelling process, removing the need for energy-intensive sintering processes
Impact
The project delivered a big breakthrough by proving that it is feasible to 3D print a solid-state battery that is less hazardous and more sustainable than conventional lithium-ion batteries. There is now the possibility of moving beyond the traditional ‘flat pack’ battery model, with the freedom to develop new shapes and forms of EV (electric vehicle) batteries.
For battery and electric vehicle manufacturers, the ability to 3D print batteries means boosted manufacturing efficiency alongside real freedom of form. This means that rather than a vehicle’s design being constrained by the size and shape of a standard battery, a battery can be made to fit into a vehicle’s design. This could enable bespoke, and high-performance EV battery applications where space is at a premium, for example in Formula E, wearables, and drones.
Following our collaboration, Photocentric has received continued funding and has been able to continue to develop the project seamlessly, delivering further promising results. As development progresses, it is expected that this method of 3D printing batteries could also result in reduced costs for manufacturers.
The UV curable formulations developed in the project could also be applied to the development of a wider range of inks for additive manufacturing and roll-to-roll printing, for example electrically conductive inks for producing IoT devices.
Related
Technologies
Markets
![](https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/191107CPI-Coxon-Building-Stock-Images_144.jpg?w=1920&h=1080&q=60&fm=jpg&fit=crop&dm=1648812265&s=60e995a698e8a2448554ba14be7bc19d 1920w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/191107CPI-Coxon-Building-Stock-Images_144.jpg?w=1120&h=630&q=60&fm=jpg&fit=crop&dm=1648812265&s=d65411545361cf28250d061ef502fb11 1120w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/191107CPI-Coxon-Building-Stock-Images_144.jpg?w=2240&h=1260&q=45&fm=jpg&fit=crop&dm=1648812265&s=37ae8c2b72c96c853e07897605ae7193 2240w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/191107CPI-Coxon-Building-Stock-Images_144.jpg?w=800&h=450&q=60&fm=jpg&fit=crop&dm=1648812265&s=e65af831aeeae1425e0e45493677740c 800w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/191107CPI-Coxon-Building-Stock-Images_144.jpg?w=1600&h=900&q=45&fm=jpg&fit=crop&dm=1648812265&s=aa7c8c46e59b1bfcb4cfb27bda71f01a 1600w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/191107CPI-Coxon-Building-Stock-Images_144.jpg?w=480&h=270&q=60&fm=jpg&fit=crop&dm=1648812265&s=218513e8177ea42fbf6169bd55432935 480w, https://optimise2.assets-servd.host/smart-hoopoe/production/content/images/191107CPI-Coxon-Building-Stock-Images_144.jpg?w=960&h=540&q=45&fm=jpg&fit=crop&dm=1648812265&s=01bea57fc8e54d32a3401d73d8a825b0 960w)