Abstract: A method of 3D printing a battery includes extruding a first electrode ink formulation through a first deposition nozzle moving relative to a substrate, and depositing one or more continuous filaments comprising the first electrode ink formulation on the substrate to print a first electrode. A separator ink formulation is extruded through a second deposition nozzle moving relative to the substrate, and one or more continuous filaments comprising the separator ink formulation is deposited on the first electrode to print a separator precursor, which is then cured to form a separator. A second electrode ink formulation is extruded through a third deposition nozzle moving relative to the substrate, and one or more continuous filaments comprising the second electrode ink formulation is deposited to print a second electrode on the separator. The first and second electrodes and the separator are enclosed in a package, thereby forming a battery with thick electrodes.

Abstract: A three-dimensional (3D) electrode architecture for a microbattery includes an anode structure comprising one or more anode digits and a cathode structure comprising one or more cathode digits, the anode digits being positioned alternately with the cathode digits in an interdigitated configuration on a substrate, where each of the anode digits has a width wa and each of the cathode digits has a width wc. Each of the anode digits comprises an anode material deposited on a first current collector and extending to a height h above the first current collector, and each of the cathode digits comprises a cathode material deposited on a second current collector and extending to a height h, above the second current collector. A height-to-width aspect ratio ha/wa of the anode structure and a height-to-width aspect ratio hc/wc of the cathode structure are at least about 2.