Abstract: A method of manufacturing a three-dimensional electrochemical lithium battery includes forming a first electrode on an underlying layer comprising aerosolizing a first ink formulation comprising a slurry including nanoparticles or microparticles of a first active material and a binder, and depositing the slurry onto the underlying layer to form a first electrode layer. A permeable separator layer is formed on the first electrode by aerosolizing a polymer precursor solution, exposing the aerosolized polymer precursor solution to a first activating radiation source to form partially cured polymer spheres in the aerosolized stream, focusing and directing the aerosolized stream onto a substrate to form the permeable separator layer of the partially cured polymer spheres, and exposing the partially cured polymer spheres on the substrate to a second activating radiation source to fully cure the partially cured polymer spheres.