EPSRC Supported EngD Project 3D-Printed Battery Electrodes Manufacturing Technology Centre (Coventry)

The complexity of future lithium-ion, sodium-ion and next generation batteries are likely to be tailored to specific applications with high performance (high energy or power density) cells used in challenging applications such as Vertical Take-Off and Landing (VTOL) aircraft whereas standard, commodity cells will be acceptable to fulfil mass market applications, like personal transport. Much of cell manufacturing is relatively low-tech, with roll-to-roll slurry coating being the preferred method for depositing electrodes. Slurry coating matches the mass-market requirements well, it is fast, low cost and has sufficient process control, but it lacks geometric freedom that may be required for very high-performance cells. Additive Manufacturing (AM) or 3D-printing of batteries offers almost unlimited freedom of design to explore, shape, geometry, chemistry and composition for high performance cells, however, fundamental research is still required into formulation and processing of the materials for deposition. This specifically involves material specification and recipe, process selection and optimisation for electrode printing.

This EngD project will look to address some of these shortcomings by investigating different additive manufacturing technologies, with novel battery chemistries, from stereo-lithography, binder-jet and laser powder-bed fusion (LPBF). This will require formulation design for the selected AM technologies and the print processes optimised to enable manufacture high performance 3D printed cells. Physical and electro-chemical modelling will be conducted to optimise performance of the designed cells with verification coming from the physical build and test. The solvents and binder materials required for AM are likely to be vastly different from those used in slurry coating.

The project will look to improve both the sustainability and green credentials of the product and process respectively by

(1) investigating next generation battery technologies; sodium, lithium, magnesium, or mixed-ion systems,

(2) removing unpleasant solvents such as NMP (1-Methyl-2-pyrrolidinone) from the manufacturing process and

(3) developing low cost and renewable binder systems with recycling and reclamation in mind,

(4) offering better material utilisation with less wastage, important particularly for expensive and scarce cathode materials used in high performance cells.

Currently we are only able to accept UK nationals. To be eligible for EPSRC funding candidates must have at least a 2(1) in an Science or Engineering or discipline or a 2(2) plus MSc. This would particularly suit someone with a materials science or chemical engineering background. To apply please email your cv to cdt-formulation@contacts.bham.ac.uk. For details on the Engineering Doctorate scheme visit the homepage. Deadline: 18th Feb 2023.

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