Researchers at the University of Texas at El Paso have developed an innovative battery component that can be manufactured in almost any shape using 3D printing technology. By eliminating the need for conventional batteries to maintain a rigid and fixed form to prevent leakage, the approach could enable energy storage units to be directly integrated into equipment such as medical devices and aerospace components. Conducted in collaboration with Sandia National Laboratories, the research uses a light-curable resin mixed with a lithium-based electrolyte instead of a conventional liquid electrolyte, enabling the material to be fabricated layer by layer.
Conventional batteries typically rely on liquids enclosed in rigid casings to prevent leakage. This limitation means that device designs often have to be shaped around the dimensions of the battery. The UTEP team overcame this constraint by transforming the electrolyte—the component responsible for transporting charged particles within the battery and enabling electricity generation—into a gel-like polymer structure. By mixing a light-curable resin with a lithium-based liquid electrolyte, the researchers created a structure that could be hardened layer by layer using a 3D printer.
One of the most notable aspects of the method is that the manufacturing process can be carried out under normal room-temperature air conditions rather than requiring a specialized oxygen-free environment. The resulting mixture, produced by adding four parts electrolyte to one part resin, achieved an ionic conductivity of 3.4 × 10⁻³ siemens per centimeter, approaching the performance of the liquid electrolytes it aims to replace. To demonstrate the design flexibility of the technology, the team printed honeycomb-like lattices and cube-shaped structures.
The project’s lead researcher, Dr. Alexis Maurel, stated that for years, the shape of devices has been determined by the battery, whereas the new technology could allow a high-performance battery component to be formed into virtually any desired shape. This development could give designers significantly greater freedom when developing device architectures. Dr. Kenith Meissner, Dean of the UTEP College of Engineering, emphasized that the combination of advanced manufacturing techniques and energy technologies could open a new era in battery design. The research team plans to further refine the material and ultimately develop fully functional battery cells.
Source: Solarbaba – In Turkish
