Fabrication of Carbon Nanotube Layer-Incorporated Stackable Cathodes by 3D Printing for High-Performance Lithium-Ion Batteries

Fabrication of thick cathodes with high mass loading is an effective way to enhance the overall energy density of lithium-ion batteries. However, sluggish ion transport in thick cathodes and poor interfacial contact with the current collector pose significant challenges for electrochemical performance and battery fabrication. To enable on-demand functionality of battery components, digital manufacturing approaches have become increasingly imperative. Herein, we propose an integrated three-dimensional (3D) printing technology to fabricate composite cathodes incorporated with carbon nanotube (CNT) layers. This CNT layer serves as a cathode current collector to ensure favorable interfacial contact and simultaneously as an ion/electronic transport layer to facilitate charge transfer within the thick cathode. The printed LiNi 0.8 Co 0.1 Mn 0.1 O 2 cathode with the CNT current collector retains 80.4% of its initial capacity after 100 cycles. For an NCM811-thick cathode with a mass loading of 35 mg·cm –2, we integrated one CNT current collector layer and two CNT transport layers. This cathode delivers an areal capacity of 6 mAh·cm –2 and retains 90% of its capacity after 60 cycles. When coupled with a graphite anode, the full cell retains 78% of its initial capacity after 100 cycles. This electrode design and fabrication strategy establishes a universal route for 3D-printed batteries and opens new avenues toward intelligent and digital battery manufacturing.