Conformal 3D printing towards shape-conformal batteries: a topical review

3D printing of batteries has received increasing attention over the past decade. Initially, 3D printing was mainly utilised to explore the potential of 3D structural electrodes to achieve enhanced electrochemical performance, as a replacement for conventional thin tape-casting electrodes. Subsequent...

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Bibliographic Details
Main Authors: Changyong Liu, Chen Li, Jie Li, Kehao Huang, Zhiyuan Liu, Zhangwei Chen, Lei Zhang
Format: Article
Language:English
Published: Taylor & Francis Group 2025-12-01
Series:Virtual and Physical Prototyping
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Online Access:https://www.tandfonline.com/doi/10.1080/17452759.2025.2461752
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Summary:3D printing of batteries has received increasing attention over the past decade. Initially, 3D printing was mainly utilised to explore the potential of 3D structural electrodes to achieve enhanced electrochemical performance, as a replacement for conventional thin tape-casting electrodes. Subsequently, 3D-printed micro-batteries, customised batteries with tailored shapes and flexible batteries have also been exploited. Conformal 3D printing of batteries onto curved substrates to realise the integration of mechanical structures and batteries towards more compact system represents the latest advance. Despite the numerous review articles on 3D printing of energy storage devices including batteries, there are no reviews that focus on the topic of conformal 3D printing towards shape-conformal batteries. Thus, this review will focus on this topic. Firstly, the significance of shape-conformal batteries is elaborated. After that, the strategies to realise shape-conformal batteries are discussed. Subsequently, we focus on the various conformal 3D printing technologies and the main characteristics of these technologies. Next, the latest advances in conformal 3D printing of shape-conformal batteries are introduced and overviewed. Finally, challenges and prospects concerning this topic are discussed. We expect that this comprehensive review may provide new insights into the 3D printing of energy storage applications.
ISSN:1745-2759
1745-2767