Printed Electronics and Additive Manufacturing: Functional Materials, Processing Techniques, and Emerging Applications: Energy Storage Devices
Sponsored by: TMS Functional Materials Division, TMS: Thin Films and Interfaces Committee
Program Organizers: Tolga Aytug, Oak Ridge National Laboratory; Pooran Joshi, Elbit Systems of America; Rahul Panat, Carnegie Mellon University; Yong Lin Kong, University of Utah; Konstantinos Sierros, West Virginia University; Changyong Cao, Case Western Reserve University ; Dave Estrada, Boise State University; Ravindra Nuggehalli, New Jersey Institute of Technology
Tuesday 8:00 AM
March 21, 2023
Room: Sapphire 411B
Location: Hilton
Session Chair: Changyong Cao, Case Western Reserve University; Majid Beidaghi, Auburn University; Konstantinos Sierros, West Virginia University
8:00 AM Invited
3D Printing of Energy Storage Devices Based on MXenes: Majid Beidaghi1; 1Auburn University
Energy storage devices (ESDs), such as batteries and electrochemical capacitors, are indispensable components of energy independent and standalone electronics. Therefore, the development of additive manufacturing (AM) technologies for the fabrication of ESDs is essential for realizing fully AM manufactured electronics. In the past several years, various AM methods have been used to fabricate 3D ESDs. Still, direct ink writing (DIW) is the most adopted AM technology for fabricating 3D devices due to its versatility in multi-material printing, lower cost, and adaptability to meet the desired structure and morphology of various ESD components. This talk will present the results of our recent studies on the formulation of inks based on two-dimensional transition metal carbides (MXenes) and DIW printing of MXene-based micro-batteries and micro-supercapacitors. The effects of the ink composition and the printing conditions on the properties of devices are discussed.
8:25 AM Invited
Synchrotron Nano-tomography and Coherent X-ray Scattering Investigation of 3D Printed Batteries: Dean Yen1; Karol Dyro1; Xiaoyin Zheng1; Cheng-Hung Lin2; David Sprouster2; Xiaojing Huang3; Mingyuan Ge3; Lutz Wiegart3; Yu-chen Karen Chen-Wiegart2; 1Stony Brook University; 2Stony Brook University / Brookhaven National Laboratory; 3Brookhaven National Laboratory
Additive manufacturing, also known as 3D printing, provides unique benefits to design energy storage micro-devices. Its versatile geometry, new architectural design, and the potential to directly integrate power sources into 3D printed devices, cannot be easily achieved with the conventional manufacturing technology. The battery materials undergo a highly non-equilibrium process during the 3D printing, resulting in different mesoscale structures which critically determine the behaviors of the printed batteries. Using operando synchrotron coherent X-ray scattering techniques, including X-ray photon correlation spectroscopy (XPCS), we are studying the dynamics of mesoscale structural formation during 3D printing. The dynamics analysis was then coupled with the 3D morphological analysis done by X-ray fluorescence tomography with a nano-probe. Additionally, environmentally friendly systems such as 3D printable aqueous batteries were also invested. Both laboratory micro-tomography and synchrotron nano-tomography were combined to enable a multi-scale visualization of the morphological evolution in the printed structure.
8:50 AM
Direct 4D Printing of Stretchable Supercapacitors Using Hybrid Composite Materials: Changyong Cao1; 1Case Western Reserve University
Stretchable supercapacitors (SCs) have attracted significant attention in developing power-independent stretchable electronic systems due to their intrinsic energy storage function and unique mechanical properties. In this talk, we will present a facile method to fabricate arbitrary-shaped stretchable electrodes via direct 4D printing of conductive nanocomposite made of reduced graphene oxide (RGO), carbon nanotube (CNT), and poly(3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOT: PSS). The electrode patterns of an arbitrary shape can be deposited onto prestretched substrates by aerosol jet printing, then self-organized origami (ridge) patterns are generated after releasing the substrates from holding stretchers due to the mismatched strains. The stretchable electrodes demonstrate superior mechanical robustness and stretchability without sacrificing its outstanding electrochemical performance. The proposed method paves avenues for scalable manufacturing of future energy-storage devices with controlled extensibility and high electrochemical performance.
9:10 AM
Creating Stretchable Solid-State Lithium Battery Arrays Using Direct Ink Writing: Nicholas Winch1; Domenic Cipollone1; Derrick Banerjee1; Harrison Loh1; Konstantinos Sierros1; 1West Virginia University
In this talk we will discuss a method to create a tailored array of lithium batteries using the direct ink writing (DIW) method in standard atmospheric conditions. The individual battery cells consist of lithium iron phosphate (LFP) cathodes, lithium lanthanum zirconium oxide (LLZO) electrolytes, and lithium titanate (LTO) anodes. The encapsulation is stretchable silicone with embedded silver wiring, serving to encapsulate, protect, and connect all individual units in the battery array. The array is designed for tailorable voltage, current and form factor to specific stretchable applications. Novel ink compositions are synthesized to provide the most facile printing and effective battery performance. Electrochemical characterizations are conducted to evaluate longevity and performance characteristics.
9:30 AM Break
9:50 AM Invited
Laser Nanostructured Al for High Performance of Al-air Batteries for Driving Drones: Anming Hu1; 1University of Tennessee
High performance Al-air batteries are attractive to replace Li-ion batteries with reducing cost and enhanced safety. In this work, we developed nanostructured Al anodes using femtosecond laser processing. We study different micro-to-nano structures to regulate the ion transporting, manage thermal dissipation during large C-rates for discharging and charging, and suppress the dendrite formation during recharging. The significant improvement of C rates is evidenced. Point-like holes, lines and grid network are compared and the optimized ratio of pore and the activated volume is probing. The roles of nanostructures and grain size are also elucidated. Our study is paving the way to apply Al-air batteries for driving drones.
10:15 AM
Additively Manufactured Sodium-ion Battery Electrodes via Digital Light Processing: Sina Bakhtar Chavari1; Bharat Yelamanchi1; Alexis Maurel2; Ana C. Martínez2; Eric MacDonald2; Cameroun Sherrard3; Pedro Cortes1; 1Youngstown State University; 2University of Texas at El Paso; 3NASA
Additive Manufacturing opens the way towards the preparation of intricate and shape-conformable batteries with enhanced specific surface area and improved electrochemical performance in term of power. Current efforts are focused on the 3D printing of sodium-ion battery negative electrodes by means of the Digital Light Processing (DLP) technology. As material feedstock for the DLP Admaflex 130 printer, a highly-loaded composite photocurable resin containing titanium dioxide and conductive additives is prepared. An optimization of the printing and thermal post-processing parameters is performed with a view to ensure adequate mechanical integrity/robustness of the electrodes as well as suitable electrochemical performances. Preliminary results suggest that the introduction of complex electrode structures with precisely controlled porosity leads to improved liquid electrolyte impregnation, better sodium ions diffusion and enhanced specific capacity values. This talk will address the structure-property relationship of 3D printed titanium dioxide/conductive carbon in terms of their mechanical, structural, and electrochemical properties.
10:35 AM Invited
Direct Ink Writing of 3D Printed Graphene Based Electrodes Material for Supercapacitors: Ying Zhang1; 1Zhengzhou University
The application of 3D printing in the field of energy storage is of great practical significance but remains extremely challenging. In this work, we fabricated free-standing electrodes with high performance by applying extrusion-based three-dimensional (3D) printing technology coupled with electrodeposition. The printable ink formulated with graphene oxide renders the printed electrodes excellent conductive skeleton for fast electron transportation, dense poly-pyrrole film was formed on the surface of the framework by electrodeposition method that contributes pseudo-capacitance, therefore, an ultralight heterous electrode with well-maintained structural integrity was prepared. Here, we systematically studied the effect of 3D printing process on the electrochemical performance of the heterogeneous electrodes, finding out the suitable printing formula. The preparation of ultralight electrodes is realized by a simple process, which provides a new idea for the large-scale production of three-dimensional electrodes and is conducive to promoting the application of 3D printing technology in the field of energy storage.