From issues to solutions: 3D printing for overcoming challenges in liquid- and solid-state batteries

3D printing, an advanced additive technology, shows promise for battery fabrication. Due to its high design flexibility, cost-effectiveness, and minimal waste generation, 3D printing has been used to create different battery components such as cathode and anode materials, solid-state electrolytes, and battery packages. Recent studies have demonstrated promising battery performances in using 3D-printed materials, benefiting from the enhanced ion/electron transport abilities. However, the practical application of 3D printing for different battery materials and fully integrated batteries is still a topic of debate. This is primarily due to the challenges to overcome the limitations of electrode materials and maximize their benefits. The effectiveness of 3D printing techniques can vary depending on the materials and printing process used. Variations in material structure and properties may require unique design structures or processing additives, so traditional 3D printing may not be suitable for addressing some materials' issues. Different 3D printing techniques can impact battery material performance, emphasizing the importance of selecting appropriate inks or structures to maximize benefits. This paper concentrates on how 3D printing can offer solutions for powder electrodes, metal electrodes, and solid-state electrolytes. It also discusses the unique capabilities of different 3D printing technologies for battery manufacturing, post-treatment processes, battery configurations, and packaging considerations. We also analyse the characteristics and limitations of 3D printing in addressing challenges with various battery materials. It aims to provide insights for advancing 3D printed batteries, paving the way for 3D printing to become an essential part of the future manufacturing industry.