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A novel super ink jet printing (SIJP) system was used to fabricate 3D zinc–silver microbatteries directly on a substrate. The SIJP provides a simple and flexible method to deposit interesting 2D and 3D structures of varying morphologies without the waste and large energy inputs typical of standard microfabrication technologies. The system was used to print pairs of silver electrodes with arrays of pillars on glass substrates, and in the presence of an electrolyte, the battery self-assembled during the first charge. Using an aqueous electrolyte solution of KOH with dissolved ZnO, the SIJP printed structures showed similar electrochemical behavior to batteries composed of silver foil electrodes. For a sparse array of pillars (∼2.5% footprint area of each electrode pad occupied by pillars), a capacity increase of 60% was achieved in comparison with a cell with planar electrodes.
Ho et al. (2009) studied this question.