en.Wedoany.com Reported - Researchers at Lawrence Livermore National Laboratory (LLNL) have developed a new 3D-printed electrode design that can enhance the performance of rechargeable batteries and supercapacitors. The design employs an interlocking three-dimensional structure that eliminates the "dead zones" in conventional planar electrodes where ions become trapped, maintaining a doubled storage capacity over 7,500 charge cycles without compromising charging speed.

Electrochemical energy storage devices typically face a trade-off between capacity and power: thick electrodes offer high capacity but hinder ion movement, thereby reducing power. The LLNL team used computational optimization and 3D printing technology to fabricate ultra-thick electrodes measuring 5.8 millimeters, whose interlocking geometry maximizes surface area and provides short, efficient pathways for ions.

The researchers used multi-material micro-stereolithography to first print a porous graphene oxide substrate to enhance ion integration, then coated it with a gold surface layer to improve conductivity. This computer-optimized "interlocking finger" structure eliminates dead zones, providing abundant channels for ions and electrons. Giovanna Bucci, a researcher in LLNL's Computational Engineering Division, stated: "In traditional flat-plate designs, a large amount of battery material is underutilized because ions cannot reach the deeper regions." In tests, the electrode demonstrated high storage capacity, low resistance, and a stable lifespan exceeding 7,500 cycles.

This 3D-printed electrode technology can be scaled up in the future for applications such as lithium-ion batteries and electric vehicles, with potential use in consumer electronics and renewable energy infrastructure. The related findings were published in the journal Materials Horizons.

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