Research on structure optimization and fabrication of energy storage materials based on additive manufacturing technology

Currently, achieving both high energy density and high-power density is the core challenge in the fabrication of energy storage materials. Despite a large number of studies having prepared high-capacity materials, some of these high-capacity active materials undergo significant volume changes during cycling, resulting in reduced material utilization and limited cycling life. Conventional fabrication processes typically yield two-dimensional planar-structured electrodes, which are difficult to achieve both high mass loading of active materials and efficient paths of electron/ion transport. In contrast, three-dimensional structures have attracted growing interest due to their capacity to enhance active material utilization, shorten ion and electron transport pathways, reduce interfacial impedance, and provide spatial accommodation for volume expansion. Additive manufacturing technology provides an effective way to fabricate energy storage materials with 3D structures by accurately constructing complex 3D structures through layer-by-layer deposition. Researchers have actively explored this area by employing AM techniques to construct ordered 3D structures that enhance ion/electron ability of transport and reaction rate of kinetics, thereby significantly improving the electrochemical performance of energy storage materials. This review systematically summarizes the application of several AM technologies in the fabrication of energy storage materials, and analyzes their respective advantages and limitations. Subsequently, we discussed in detail the advantages of AM technology in the fabrication of energy storage materials and several main optimization strategies that can be achieved. Finally, the review addresses the major challenges and potential applications of AM technology in energy storage material optimization.