Laser-based three-dimensional manufacturing technologies for rechargeable batteries

Abstract

Laser three-dimensional (3D) manufacturing technologies have gained substantial attention to fabricate 3D structured electrochemical rechargeable batteries. Laser 3D manufacturing techniques offer excellent 3D microstructure controllability, good design flexibility, process simplicity, and high energy and cost efficiencies, which are beneficial for rechargeable battery cell manufacturing. In this review, notable progress in development of the rechargeable battery cells via laser 3D manufacturing techniques is introduced and discussed. The basic concepts and remarkable achievements of four representative laser 3D manufacturing techniques such as selective laser sintering (or melting) techniques, direct laser writing for graphene-based electrodes, laser-induced forward transfer technique and laser ablation subtractive manufacturing are highlighted. Finally, major challenges and prospects of the laser 3D manufacturing technologies for battery cell manufacturing will be provided.

Keywords: Additive manufacturing; Laser manufacturing; Rechargeable batteries; Subtractive manufacturing; Three-dimensional printing.

Fig. 1

a Schematic illustration of powder bed fusion additive manufacturing process [59]. b Schematic illustration of directed energy deposition additive manufacturing process [53]

Fig. 2

Schematic illustration of a the photothermal process within the laser writing of graphene electrode; the inset image demonstrates the thermal breaking between C and O–H bonds. b The photochemical process within the laser writing of graphene electrode; the inset image demonstrates the photon induced disassociation of band between C and O–H. c The laser induced forward transfer of graphene based on the roll-to-roll production with a polyimide film [76]

Fig. 3

a Schematic illustration of the LIFT of liquid films. The pulsed laser beam is translated along the scan direction and a liquid jet is formed upon laser irradiation which transfer the donor material to the receiving substrate. b Stop action movie of the LIFT process show the jetting dynamics characteristic [91]

Fig. 4

a Schematic illustration of the 3D Si@C core–shell electrode. b SEM images of the 3D Si@C core–shell electrodes. c Rate performances of the Si@C and 3D Si@C core–shell cells at various current densities of 0.2, 0.4, 0.8, 1, 2, 4, 8, and 0.2 A/g (cut-off voltage: 0–2 V) [128]