Australian metal 3D printer manufacturer Titomic has partnered with Rensselaer Polytechnic Institute (RPI) to conduct a multi-stage development evaluating cold spray additive manufacturing (CSAM) technology for lithium-ion battery electrode manufacturing.
Most lithium ion battery electrodes are commonly produced through slurry based processes that involve mixing active materials, coating metal foils, drying, and calendaring. Backed by the US-based National Science Foundation (NSF) Energy Storage Engine program in Upstate New York, this collaboration is investigating whether CSAM can be used to apply electrode powders directly onto aluminum or copper foils.
This approach removes the need for solvents, binders, and drying steps, making the process compatible with roll-to-roll manufacturing environments.
“By applying our proven TKF cold spray technology to battery electrode manufacturing, Titomic is helping to overcome long-standing efficiency and sustainability challenges in lithium-ion production. This development not only benefits our customers but also supports the global transition to renewable energy and electrification,” said Jim Simpson, Titomic CEO and Managing Director.
Evaluating CSAM for battery electrodes
For this project, the technical work will be carried out as a four phase program that begins with material feasibility studies. Initial efforts will focus on depositing anode and cathode powders, including silicon, lithium titanate, lithium manganese oxide, and lithium iron phosphate, onto foil substrates, after which the deposited layers will be examined using micro level and macro level characterization to determine appropriate spray parameters for each material system.
In addition to conventional electrode materials, the cold spray approach can support silicon-based composite anodes designed to deliver higher theoretical energy capacity.
As that work progresses, the program will move into a down selection stage and the development of electrode demonstrators. These demonstrators will be designed to meet industry requirements and will undergo electrochemical testing to verify performance characteristics.
With laboratory work complete, attention will then turn to deployment of a pilot scale cold spray station integrated into a customer lithium ion battery roll to roll production line, allowing the process to be evaluated under industrial manufacturing conditions rather than in a research environment. The final stage will focus on detailed analysis of scalability and production costs, building on data generated during the laboratory and pilot phases.
“Titomic’s dedicated cold spray systems enable direct and high-throughput deposition of LIB electrodes, helping to accelerate the transition toward renewable energy adoption and widespread electrification,” said Prof. Semih Akin and Prof. Nikhil Koratkar, NSF project PIs from RPI.
3D printed batteries show performance gains
3D printing of lithium-ion batteries enables highly customized and architected electrodes that can significantly improve power performance and enable novel form factors, with promising applications in microbatteries and structural energy storage.
In line with this, Tel Aviv University and Rafael Advanced Defence Systems researchers demonstrated the first fully inkjet drop-on-demand (DoD) 3D printed lithium-ion battery, fabricating the cathode, separator, and anode layer by layer. Using tailored inks for an LFP cathode, a porous PVdF–alumina separator, and a graphite-based anode, the team achieved precise deposition with controlled nozzle sizes.
Electrochemical testing showed performance comparable to conventional cells, including stable cycling, high coulombic efficiency, and effective ion transport. The results highlighted DoD printing as a viable route for customized, miniaturized energy storage devices.
Last month, battery 3D printing specialist Sakuu reported new performance results for lithium-ion battery electrodes produced on its Kavian Manufacturing Platform, demonstrating long-cycle durability using a fully dry printing process. A lithium-ion test cell with a 1Ah capacity, using a dry-printed nickel-cobalt-manganese (NCM811) cathode and a graphite anode, retained 83% of its capacity after 4,000 charge–discharge cycles at a 1C rate, outperforming typical commercial NCM cells.
The result was achieved without new materials or additional optimization. Sakuu stated that Kavian supported dry printing across multiple electrode chemistries while reducing solvents, emissions, factory footprint, and production costs compared with conventional wet manufacturing.
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Featured image shows a Titomic TKF 3D printer. Photo via Titomic.
