Researchers at Shenzhen Technology University have published an overview in which 3D printing can accelerate the development of aqueous zinc-ion batteries (AZIBS), a promising alternative to lithium-ion systems. The work, the recent progress in research on 3D printing in aqueous zinc-ion batteries, was published on August 4, 2025 in Polymers.
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Secure and sustainable energy storage
In view of the increasing demand for integration of renewable energies, the researchers are looking for safer and more sustainable alternatives to lithium-ion batteries. Azibs offer advantages, including cost -effective, abundant raw materials and non -inflammatory aqueous electrolytes. However, traditional manufacturing techniques limit performance due to challenges such as zinc -dendrite growth, inefficient ion transport and unstable electrodes electrolyte border areas.
According to the authors, 3D printing offers a new design freedom for combating these bottlenecks. Additive production enables customer -specific electrode architectures, controlled ion paths and integrated cell packaging, which makes you a potential player for the next generation's battery production.
Printing techniques that are evaluated
The study examines the role of three important additive manufacturing methods in zinc-ion battery research. Direct ink Writing (DIW) enables the exact production of thick, porous electrodes and solid electrolyte structures. By supporting Hochvisko ink, it enables adaptation of ion channels, although it still has challenges with ink formulation and relatively slow pressure speeds.
In contrast, Fused Filament Fabrication (FFF) offers an inexpensive and widely accessible route for the production of battery houses and current collector forms. However, this approach is limited by low electrical density and limited material compatibility.
The stereolithography (SLA) provides undermikric accuracy and is particularly suitable for microfluidic electrolytes and thin solid electrolytic layers. However, it remains restricted by the need for Fototothärerer harter harse and often requires complex post -processing.
Each of these technologies offers unique advantages for different battery components. However, all must overcome restrictions on scalability and long -term stability.
Applications in Azib design
In the review, some current examples of this are emphasized how 3D printing was applied to key components of aqueous zinc-ion batteries. For cathodes, 3D printed MNO and FEVO/RHGO structures with porous or honeycomb geometries improved the cycle stability and ion transport, whereby the surface capacities over 7 mAh/cm² are reached.
On the anode side, researchers used stereolithography and direct writing from inks to create three-dimensional zinc and graphs frameworks that suppressed dendrit growth and longer battery life for more than 1,800 hours.
Electrolytes and degrees have also benefited from additive manufacturing: on a hydrogel base, printed electrolytes that were printed via DIW and DLP provided high ionic conductivity and mechanical flexibility, which made them suitable for portable devices, while Mxenmodified separators further stabilized.
Finally, the full cell packaging was demonstrated by directly printed microtatteries and hybrid capacitors, which showed improved structural integration, an improved lifespan of the cycle and compatibility with flexible electronics.
Obstacles for the scaling of 3D printed zinc-ion battery
Despite encouraging results, the scaling of 3D-printed AZIBs for industrial production remains a hurdle. Material printability, interior compatibility and process efficiency must be tackled in addition to robust quality control systems.
The authors suggest that future progress will be based on multi-material printing, AI-controlled process optimization and in situ monitoring structural development. They conclude from the fact that the combination of material innovations with structural optimization could enable 3D printing AZIBs to play an important role in safe, sustainable energy storage
Expand the extension of additive manufacturing beyond lithium ions
This review comes in the middle of a growing wave of innovation, in which additive production fundamentally changes the design of the battery components through chemicals. For example, the latest examinations for 3D printing improve the lithium-ion systems: In an article, it is examined how techniques such as DIW, SLA, FDM and binder ditting create custom electrode microstructures with superior porosity and cycle duration.
Another highlighted groundbreaking shape -compliant batteries that are printed directly on curved or flexible surfaces using aerosol beam printing that seamlessly integrate batteries into compact devices. In the past, researchers from CalTech showed the potential of the DLP-based 3D printing for the formation of complex electrode geometries for Li-ion batteries and show how additive methods can drive both precision and performance.
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The picture presented shows a schematic representation of challenges in the electrode electrolyte border area in Azibs and strategies. Image about polymers.