3d-printing of Energy Devices Using Particle-based Inks

Introduction and Summary Over the past year, ISEN funding has been utilized to make significant research progress towards the fabrication of a fully 3D-printed iron/solid oxide fuel cell (Metallic/multi-ceramic) batterygenerator system (Figure 1). Monies have gone towards the partial funding of one grad student/postdoc, Adam Jakus, in Ramille Shah’s Tissue Engineering and Additive Manufacturing laboratory; supporting his efforts to develop the 3D-printable particle-based metallic and ceramic inks, their subsequent characterization and 3D-printing, and post-processing and evaluation of the 3D-printed metallic and ceramic structures. In addition to partially funding his stipend/salary, ISEN monies were utilized to purchase raw materials to be 3D-printed, 3D-printer consumables, and postprocessing materials (i.e. H2 gas), as well paying for facility use and time for sample preparation and characterization. The successful fabrication of the iron-air battery energy storage and generating system depicted as “3” in Figure 1, relies on the success of three distinct research efforts: 1. Developing reliable and consistent particle-based, liquid, 3D-printable inks from metallic, metal-compound, and ceramic powder materials, 2. Transforming the 3D-printed metallic or metal oxide structures into complex, cellular, sintered metallic objects without warping or cracking, and 3. 3D-printing the ceramic, SOFC related inks into multi-material constructs representative of SOFCs. Although we have yet to combine the metallic and ceramic systems into a functional device, the ISEN funding has provided the support needed to establish efforts 1-3, and we will soon have the knowledge and protocols required to economically create a fully 3D-printed, complex metalceramic system capable of storing and generating energy that could not be produced using any existing fabrication or manufacturing method.