The Secret Revolution in Battery Technology: 3-D Printing (msn.com) 1
"There's a revolution in battery technology hiding in plain sight," reports The Wall Street Journal. "The 3-D printing of batteries has the potential to put energy storage inside any device.
"This will enable lightweight and long-lasting consumer gadgets, long-range military drones and even nanoscale robots." Almost all the innovations we regularly hear about — from cheaper, tougher electric-vehicle batteries to "Holy Grail" solid-state batteries — are about changing the chemistry of batteries. The promise of battery-tech 3-D printing (aka additive manufacturing) is simple: What if batteries could fill any available space, even structural elements of our gadgets, rather than always taking a rigid shape like a pouch or cylinder?
The new approach has obvious appeal. The entire airframe of a drone could be filled with energy storage for increased range. Smartglasses could have sleek battery-packed frames, so they look like everyday eyewear rather than "Revenge of the Nerds" props. One of the biggest advantages of 3-D printing is that it works with any battery, regardless of its cell chemistry. It could advance today's lithium-ion as well as emerging sodium-ion and solid-state tech... Some [startups] are trying to use 3-D printing to create efficiencies in existing battery manufacturing systems. A brave handful of startups are pursuing radical new designs and approaches. They're starting with defense applications, where cost and scale are less of an issue...
At Silicon Valley-based Sakuu... [r]ather than trying to 3-D-print whole batteries, the company is working on replacing one of battery manufacturing's biggest pain points, says Arwed Niestroj, Sakuu's chief operating officer, who is also a nuclear physicist and former head of Mercedes-Benz Research & Development North America. Existing battery assembly lines include football-field-long ovens for drying layers of material that have been dissolved in solvents. This requires a huge amount of energy and is a significant contributor to manufacturing costs, a big reason EV batteries aren't cheaper. Sakuu's process, under development for years, uses additive manufacturing to lay down key battery components without solvents, eliminating the need for ovens, says Niestroj.
Sakuu is currently working to commercialize this tech with a major battery manufacturer...
"This will enable lightweight and long-lasting consumer gadgets, long-range military drones and even nanoscale robots." Almost all the innovations we regularly hear about — from cheaper, tougher electric-vehicle batteries to "Holy Grail" solid-state batteries — are about changing the chemistry of batteries. The promise of battery-tech 3-D printing (aka additive manufacturing) is simple: What if batteries could fill any available space, even structural elements of our gadgets, rather than always taking a rigid shape like a pouch or cylinder?
The new approach has obvious appeal. The entire airframe of a drone could be filled with energy storage for increased range. Smartglasses could have sleek battery-packed frames, so they look like everyday eyewear rather than "Revenge of the Nerds" props. One of the biggest advantages of 3-D printing is that it works with any battery, regardless of its cell chemistry. It could advance today's lithium-ion as well as emerging sodium-ion and solid-state tech... Some [startups] are trying to use 3-D printing to create efficiencies in existing battery manufacturing systems. A brave handful of startups are pursuing radical new designs and approaches. They're starting with defense applications, where cost and scale are less of an issue...
At Silicon Valley-based Sakuu... [r]ather than trying to 3-D-print whole batteries, the company is working on replacing one of battery manufacturing's biggest pain points, says Arwed Niestroj, Sakuu's chief operating officer, who is also a nuclear physicist and former head of Mercedes-Benz Research & Development North America. Existing battery assembly lines include football-field-long ovens for drying layers of material that have been dissolved in solvents. This requires a huge amount of energy and is a significant contributor to manufacturing costs, a big reason EV batteries aren't cheaper. Sakuu's process, under development for years, uses additive manufacturing to lay down key battery components without solvents, eliminating the need for ovens, says Niestroj.
Sakuu is currently working to commercialize this tech with a major battery manufacturer...