Inkjet-Printed Silver Lithiophilic Sites on Copper Current Collectors: Tuning the Interfacial Electrochemistry for Anode-Free Lithium Batteries

Anode-free lithium batteries (AFLBs) present an opportunity to eliminate the need for conventional graphite electrodes or excess lithium–metal anodes, thus increasing the cell energy density and streamlining the manufacturing process. However, their attributed poor coulombic efficiency leads to rapid capacity decay, underscoring the importance of achieving stable plating and stripping of Li on the negative electrode for the success of this cell configuration. A promising approach is the utilization of lithiophilic coatings such as silver to mitigate the Li nucleation overpotential on the Cu current collector, thereby improving the process of Li plating/stripping. On the other hand, inkjet printing (IJP) emerges as a promising technique for electrode modification in the manufacturing process of lithium batteries, offering a fast and scalable technology capable of depositing both thin films and patterned structures. In this work, a Fujifilm Dimatix inkjet printer was used to deposit Ag sites on a Cu current collector, aiming to modulate the interfacial electrochemistry of the system. Samples were fabricated with varying areas of coverage and the electrochemical performance of the system was systematically evaluated from bare Cu (non-lithiophilic) to a designed pattern (partially lithiophilic) and the fully coated thin film case (lithiophilic). Increasing lithiophilicity resulted in lower charge transfer resistance, higher exchange current density and reduced Li nucleation overpotential (from 55.75 mV for bare Cu to 13.5 mV for the fully coated case). Enhanced half-cell cyclability and higher coulombic efficiency were also achieved (91.22% CE over 76 cycles for bare Cu, 97.01% CE over 250 cycles for the fully coated case), alongside more uniform lithium deposition and fewer macroscopic irregularities. Moreover, our observations demonstrated that surface patterning through inkjet printing could represent an innovative, easy and scalable strategy to provide preferential Li nucleation sites to guide the subsequent Li deposition.