Recent advances in fabrication strategies for high-performance solid-state batteries: Overcoming interfacial challenges and enabling scalable, cost-effective manufacturing

The better energy density, improved safety, and longer cycle life of solid-state batteries (SSBs) make them a promising energy storage technology. Interfacial instability and manufacturing scalability still plague large-scale commercial adoption. Interface-engineered, Next Generation, Tailored, Energy-dense, Green, Reliable, Additive-manufactured, thermally stable, Economical (INTEGRATE) is a scalable fabrication strategy that leverages 3D printing, atomic layer deposition, and plasma-assisted processing. Our framework improves ion transport across the electrode–electrolyte interface, structural alignment during multilayer assembly, and mechanical compatibility under operational stress. Ionic conductivity of 0.025 S/cm at 338 K, 95% capacity retention after 250 cycles, 93% cycle-life retention over 500 cycles, $2.50 per cell fabrication cost, scalable production throughput of 260 units/hour, and 28% failure rate at 50 MPa are experimentally verified. The room-temperature ionic conductivity is 35% higher and the manufacturing cost is 25% lower than that of current methods. The INTEGRATE framework is a technically robust and economically scalable platform for high-performance SSB manufacturing, with strong potential for commercial deployment in electric vehicles, consumer electronics, and grid-scale energy storage systems, advancing next-generation sustainable energy technologies.