Additive manufacturing of functional high-performance polymers for energy storage, conversion, and insulation systems

Energy-related systems require materials that not only withstand harsh operating conditions, including extreme temperatures, corrosive environments, mechanical stresses, and radiation, but also can be manufactured into complex geometries (e.g. porous networks, patterned membranes, and architected 3D lattices etc.) and integrated structures to deliver specific functionalities such as insulation, separation, membrane operation, energy storage, or shielding. Traditional methods like molding and machining often struggle to create intricate multifunctional components such as porous scaffolds, interdigitated electrodes and layered membranes. In contrast, advances in additive manufacturing (AM) have transformed the production of energy-related components by enabling greater design freedom, rapid prototyping, and the fabrication of customized, high-performance parts with reduced material waste. Among the different classes of AM, high-performance polymers (HPPs) have emerged as promising candidates due to their outstanding thermal, mechanical, and chemical resilience. These, including Polyamide (PA), Polyetherimide (PEI), Polyphenylene Sulfide (PPS), Polysulfone (PSU), Polyetheretherketone (PEEK), and Polyimide (PI), are particularly suited for AM in demanding energy applications. This review summarizes recent advances in the AM of HPPs for electrochemical and thermal energy storage, hydrogen production and storage, oil and gas systems, and radiation shielding. It also examines how structural design and composite reinforcement enhance performance, and outlines current challenges and future research directions to advance AM technologies for energy-related applications. • Maps FFF, L-PBF, and DIW to smart, architected energy components and use-case trade-offs. • Benchmarks HPPs for harsh energy environments and AM printability. • Shows AM-engineered parts boosting ion transport, conductivity, and capacity via lattice design and fillers. • Outlines challenges and a roadmap for multifunctional, smart HPP composites in energy systems.