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Optimizing Cathode Structure for Enhanced Electrochemical Performance Using 3D-printed Lattice Structures

Project Description:

This project aims to improve the performance of solid-state batteries by redesigning the cathode structure using 3D printing. Traditional cathodes limit ion and electron transport due to disorganized internal pathways. To address this, we use 3D-printed polymer lattice molds made from polycarbonate-carbon fiber (PC-CF) to guide the structure of lithium iron phosphate (LFP) cathodes. The PC-CF decomposes during sintering, leaving behind organized channels that enhance conductivity. We optimized printing parameters using the Prusa i3 Mk3S+ and tested materials using optical microscopy, DSC/TGA, and Raman spectroscopy. This method allows precise control over porosity and tortuosity to improve battery efficiency, durability, and safety.

Project Photo:

A 3D-printed lattice structure shown above a schematic of a composite cathode. The schematic illustrates how the printed lattice forms vertical and horizontal channels that improve ion and electron transport from the current collector through the cathode.

3D-printed lattice molds create structured channels within the cathode, improving ion and electron transport. This design reduces tortuosity and enhances conductivity, leading to better battery performance.

Student Team Members

Robbin Bai

Course Faculty

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