U.S. Uses 3D Printers to Create Sand-sized Microbatteries

2025-08-10 12:05:09

According to a report from the Physicist Organization Network on June 18, a team of researchers from Harvard University and the University of Illinois at Urbana-Champaign have created a groundbreaking 3D-printed lithium-ion microbattery. Surprisingly, this tiny power source is no larger than a grain of sand and can be electrified. Despite its size, it delivers performance that rivals commercial batteries. Microbatteries like this could revolutionize fields such as medical devices, communication systems, and more—especially for small-scale innovations still in the lab phase that lack a suitable power source. The findings were recently published online in the journal "Advanced Materials."

In recent years, engineers have developed numerous micro-devices, including medical implants, flying insect-like robots, and miniaturized cameras and microphones. However, the batteries powering these devices are often bulkier than the devices themselves, which contradicts the goal of miniaturization. Traditional methods of creating electrode layers result in solid-state micro-batteries with limited energy storage due to their ultra-thin design. To overcome this, researchers aim to develop ultra-thin electrodes that are tightly layered and interwoven, allowing for greater energy capacity.

The project was led by Jennifer Lewis, a professor at the Wyss Institute for Biologically Inspired Engineering at Harvard’s School of Engineering and Applied Sciences. Her team designed a range of functional “inks” with unique chemical and electrical properties. Using these inks and specialized 3D printers, they can fabricate complex structures with electrical, optical, or biological functions, significantly expanding the potential of 3D printing technology.

To create microelectrodes, the researchers developed and tested several special “inks” that mimic electrochemical materials and can be extruded like toothpaste. Once printed, these inks harden into thin, functional layers. They used lithium oxide nanoparticles for the anode ink and another material for the cathode ink, forming a multi-layered structure where the anodes and cathodes are closely intertwined—each layer thinner than a human hair. These electrodes were then placed into tiny containers and filled with an electrolyte solution.

The team also evaluated the battery’s charge capacity, charging time, and overall performance. “In terms of charge and discharge rates, cycle life, and current output, the electrochemical performance of our microbattery is comparable to that of commercial batteries. We’ve simply scaled it down,” said Xin Dillon, an associate professor of materials science and engineering at the University of Illinois and co-author of the study.

Donald Ingber, director of the Wyss Institute, added, “The Jennifer Lewis team has redefined the design of microbatteries, greatly expanding the practical applications of 3D printing and opening up new possibilities for miniaturizing various types of equipment.”

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