Additive Manufacturing for Li-Ion Batteries (Phase II)

Physical Sciences Inc. (PSI) will construct and demonstrate Li-ion cells for Naval Aviation applications using solvent free additive manufacturing techniques. Lithium-ion batteries simultaneously offering high energy and power density will be demonstrated using novel solvent-free electrode feedstocks. PSI will work with the Complex Fluids Lab (CFL) at the University of Connecticut to optimize the rheology of the feedstock and to manufacture electrodes using extrusion based additive manufacturing. The extrusion-based additive manufacturing process will be a scalable production method to produce high performance components and complete lithium-ion cells. Anode and cathode electrodes will first be demonstrated as individual drop-in components in existing Li-ion cell designs before being integrated together in a planar pouch cell. Further, PSI in conjunction with the CFL, will produce 3D lithium-ion cells using printed interdigitated electrodes that match the energy density of planar cells while providing >10% increase in power performance. Cycle life testing and 3D cell scale-up will continue into the Phase II option. PSI will prepare a Phase III development plan that will outline scale-up of the technology to support production of higher performance cells for Navy applications. PSI anticipates manufacturing the designed battery for multiple applications.