High energy density lithium batteries via 3D printing technologies: A review

The rapid development of clean energy technologies has imposed higher requirements on the energy density of lithium batteries. However, conventional battery manufacturing techniques exhibit inherent limitations in precisely controlling geometric architectures and interface engineering of battery components, consequently restricting mass transport processes and failing to realize the full energy density potential of lithium batteries. As an intelligent manufacturing technology, 3D printing offers effective solutions to these challenges through freeform fabrication of battery components. This review systematically analyzes 3D printing advances for lithium batteries, assessing each method's strengths and limitations while exploring their applications in high-energy-density systems. Key innovations include: thick electrodes with enhanced ion transport; porous frameworks for Li-S, Li-air, Li-metal batteries offering abundant active sites and more space to inhibit the volume expansion and lithium dendrite growth; optimized electrode/solid-state electrolyte interfaces; and customized microbatteries. Current challenges in materials, equipment precision, and process optimization are discussed, along with future research directions.