From Sulfur to Power: 3D-Printed Batteries for a Net-Zero World

Authors

Mahmoud Kaid, Virginia Commonwealth University

Original Publication Date

2026

Document Type

Video

Comments

Presented in the Precision Materials for a Sustainable World session

Abstract

This presentation addresses the limitations of lithium-ion batteries by developing high-performance rechargeable lithium-sulfur (Li-S) batteries. While Li-S chemistry offers up to six times the energy density of Li-ion systems using abundant, low-cost sulfur, it traditionally suffers from the "shuttle effect", where soluble intermediates cause capacity loss—and a significant performance drop when electrodes are thickened for commercial use.

To overcome the "thickness paradox," in which ion diffusion fails to reach the bulk of thick, cast electrodes, the researcher used Direct Ink Writing (3D printing) to create graded electrodes with open micro-channels.

Key breakthroughs include:

• Structural Design: 3D-printed channels enable 100% sulfur utilization by facilitating fast ion diffusion throughout the electrode bulk.
• Mass Efficiency: By printing directly onto battery cases, the design eliminates inactive aluminum current collectors, increasing overall energy density.
• Performance Gains: The 3D-printed cells achieved an areal capacity of 12.5 mAh/cm² (a six-fold increase over conventional casting) and an energy density of 312 Wh/kg.
• Stability: The battery demonstrated robust longevity, retaining 85% capacity after 1,000 cycles.

The findings suggest that structural architectural modifications via 3D printing are essential to scale Li-S technology for real-world energy storage.

Keywords

Lithium-Sulfur (Li-S) batteries, 3D printing, Direct Ink Writing (DIW), Energy density

Rights

Copyright © 2026 Mahmoud Kaid. All rights reserved.