Next‐Generation Additive Manufacturing of Complete Standalone Sodium‐Ion Energy Storage Architectures

The first entirely AM/3D‐printed sodium‐ion (full‐cell) battery is reported herein, presenting a paradigm shift in the design and prototyping of energy‐storage architectures. AM/3D‐printing compatible composite materials are developed for the first time, integrating the active materials NaMnO 2 and TiO 2 within a porous supporting material, before being AM/3D‐printed into a proof‐of‐concept model based upon the basic geometry of commercially existing AA battery designs. The freestanding and completely AM/3D‐fabricated device demonstrates a respectable performance of 84.3 mAh g −1 with a current density of 8.43 mA g −1 ; note that the structure is typically comprised of 80% thermoplastic, but yet, still works and functions as an energy‐storage platform. The AM/3D‐fabricated device is critically benchmarked against a battery developed using the same active materials, but fabricated via a traditional manufacturing method utilizing an ink‐based/doctor‐bladed methodology, which is found to exhibit a specific capacity of 98.9 mAh m −2 (116.35 mAh g −1 ). The fabrication of fully AM/3D‐printed energy‐storage architectures compares favorably with traditional approaches, with the former providing a new direction in battery manufacturing. This work represents a paradigm shift in the technological and design considerations in battery and energy‐storage architectures.