Contemporary Micro-Battery Technologies: Advances in Microfabrication, Nanostructuring, and Material Optimisation for Lithium-Ion Batteries

The miniaturisation of electronic devices has intensified the demand for compact, high-performance lithium-ion batteries. This review synthesises recent progress in microscale battery development, focusing on microfabrication techniques, nanostructured materials, porosity-engineered architectures, and strategies for reducing non-active components. It explores both top–down and bottom–up fabrication methods, the integration of nanomaterials, the role of gradient electrode architectures in enhancing ion transport and energy density, along with strategies to reduce non-active components, such as separators and current collectors, to maximise volumetric efficiency. Advances in top–down and bottom–up fabrication methods, including photolithography, laser structuring, screen printing, spray coating, mechanical structuring, and 3D printing, enable precise control over electrode geometry and enhance ion transport and material utilisation. Nanostructured anodes, cathodes, electrolytes, and separators further improve conductivity, mechanical stability, and cycling performance. Gradient porosity designs optimise ion distribution in thick electrodes, while innovations in ultra-thin separators and lightweight current collectors support higher energy density. Remaining challenges relate to scalability, mechanical robustness, and long-term stability, especially in fully integrated micro-battery architectures. Future development will rely on hybrid fabrication methods, advanced material compatibility, and data-driven optimisation to bridge laboratory innovations with practical applications. By integrating microfabrication and nanoscale engineering, next-generation LIBs can deliver high energy density and long operational lifetimes for miniaturised and flexible electronic systems.