Publication date: 21st July 2025
The development of thick, high-loading electrodes is essential to increase the energy density and reduce the cost of next-generation solid-state batteries (SSBs). In this work, we explore advanced ceramic shaping techniques, such as Powder Injection Moulding (PIM), Powder Extrusion Moulding (PEM), and Fused Filament Fabrication (FFF), to fabricate additive-free thick electrodes based on commercial and available ceramic active powders, such as Li₄Ti₅O₁₂ (LTO), LiFePO4, LiCoO2, NMC, NCA. These shaping routes allow the fabrication of robust, binder-free electrodes with precisely controlled geometries and high mass loadings (>100 mg·cm⁻²), while maintaining mechanical integrity and suitable porosity for ionic and electronic transport [1, 2, 3].
The feedstocks are formulated using thermoplastic binders and optimized through rheological studies to ensure homogeneous dispersion and extrusion behaviour. After shaping, debinding and sintering steps yield robust ceramic structures with thicknesses up to 300-500 μm and open porosities in the 20–30% range. Electrochemical testing in half- and full-cell configurations confirms excellent cycling stability and demonstrates high areal and volumetric capacities—>15 mAh·cm⁻² and >315 mAh·cm⁻³ for 500 μm electrodes fabricated via PEM, and 25 mAh·cm⁻² and 400 mAh·cm⁻³ for 650 μm electrodes fabricated by PIM [1,4]. Notably, the use of FFF enables the fabrication of electrodes with even greater thicknesses (~800 μm) and ultra-high mass loadings (285 mg·cm⁻²), achieving outstanding areal and volumetric capacities of 28 mAh·cm⁻² and 354 mAh·cm⁻³, respectively [5]. The scalable and versatile nature of these ceramic shaping techniques paves the way for the integration of structured and 3D-architectured electrodes in advanced SSB architectures.
Overall, our results demonstrate that ceramic forming technologies originally developed for structural ceramics can be successfully adapted to the fabrication of electrochemical devices, offering an effective route toward compact, high-performance solid-state batteries.
The authors would like to thank the Agencia Estatal de Investigación (Spain)/Fondo Europeo de Desarrollo Regional (FEDER/European Union) MCIN/AEI/10.13039/501100011033 (project PID2022-140373OB-I00) and Madrid Government (Comunidad de Madrid-Spain) (DROMADER-CM (Y2020/NMT6584)) for funding.
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