Advances in solid-state batteries fabrication strategies for their manufacture

Abstract

Solid-state batteries (SSBs) are regarded as safer and potentially more energy-dense alternatives to conventional liquid electrolyte-based batteries. However, their current estimated cost exceeds $100/kWh due to the high material processing costs and low-throughput manufacturing methods. Furthermore, SSBs that operate efficiently at room temperature with high energy and power density have yet to be demonstrated, primarily due to internal challenges such as low ionic conductivity at the electrode-solid-state electrolyte (SSE) interfaces. Conventional SSB designs must address issues including the volume changes in active materials, the mechanical properties of the components, and the overall sustainability of the fabricated device. There is a critical need to enhance surface contact at the interfaces, match grain boundary levels across materials, and achieve high ion transport at room temperature in all-solid-state batteries (ASSBs). As the demand for scalable, high-throughput, reliable, and cost-effective fabrication processes grows, research is increasingly focused on developing such methods. This review examines recent advances in promising fabrication technologies, including 3D printing (3DP), plasma technology, and atomic layer deposition (ALD), with an emphasis on improving the electrode-electrolyte interface for high-performance SSBs. Additionally, the challenges associated with these fabrication techniques and potential future developments are discussed.