In recent years, lithium-ion batteries, which power everything from smartphones to electric vehicles, have significantly improved in terms of safety and energy density. Solid-state batteries will make batteries safer by eliminating the flammable liquid electrolyte found in today’s cells, but they will also increase energy density and allow faster charging. Saku, a California-based startup, believes that 3D printing will allow them to create much more efficient space use and deliver many higher-capacity batteries.
Saku developed a 10-meter-long multi-material printer capable of printing ceramics and metals. The machine first deposits powdered material patterns before stashing a jet of polymer binder that binds the particles together. The conductive metal is then deposited on top. Cells are formed by stacking these layers on top of each other. As a result, it can provide 100% more capacity than current lithium-ion cells while making batteries 50% smaller and 40% lighter. A further notable benefit of 3D printing is the ability to create barrages in various shapes, which is difficult to achieve with conventional roll-to-roll manufacturing.
Batteries could be built into the structural system of products using the process described above, eliminating the need to dedicate space for them. The electric vehicle industry’s primary focus has become increasing the battery capacity of their vehicles without adding extra weight. Contemporary Amperex Technology, a Chinese battery manufacturer, and Leapmotor, a manufacturer of electric vehicles, are working together to integrate batteries into car chassis. Synchronously, Tesla has developed a new glue that will enable its batteries to be load-bearing and used as structural parts.
If Saku can get their printers working, they will be able to increase the range and reliability of electric vehicles, bringing them closer to the mainstream.
