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

Achieving high energy and power densities is currently a core challenge in the fabrication of energy storage materials. Although numerous high-capacity materials have been developed, conventional planar electrodes cannot achieve high active material loading and efficient ion/electron transport simultaneously. By contrast, three-dimensional (3D) structures have attracted increasing interest because of 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 (AM) technology effectively fabricates energy-storage materials with 3D structures by accurately constructing complex 3D structures via layer-by-layer deposition. Recent studies have employed AM to construct ordered 3D electrodes that can optimize ion/electron transport, regulate electric field distribution, or improve the electrode–electrolyte interface, thereby contributing to enhanced kinetic performance and cycling stability. This review systematically summarizes the applications of several AM technologies in the fabrication of energy storage materials and analyzes their respective advantages and limitations. Subsequently, the advantages of AM technology in the fabrication of energy storage materials and several major optimization strategies are comprehensively discussed. Finally, the major challenges and potential applications of AM technology in energy storage material optimization are discussed.