Additive manufacturing can enable the fabrication of batteries in nonconventional form factors, enabling higher practical energy density due to improved material packing efficiency of power sources in devices. Furthermore, energy density can be improved by transitioning from conventional Li-ion battery materials to lithium metal anodes and conversion cathodes. Iron disulfide (FeS2) is a prominent conversion cathode of commercial interest; however, the direct-ink-write (DIW) printing of FeS2 inks for custom-form battery applications has yet to be demonstrated or optimized. In this work, DIW printing of FeS2 inks is used to systematically investigate the impact of ink solid concentration on rheology, film shape retention on arbitrary surfaces, cathode morphology, and electrochemical cell performance. We find that cathodes with a ridged interface, produced from the filamentary extrusion of highly concentrated FeS2 inks (60-70% solids w/w%), exhibit optimal power, uniformity, and stability when cycled at higher rates (in excess of C/10). Meanwhile, cells with custom-form, wave-shaped electrodes (printed FeS2 cathodes and pressed lithium anodes) are demonstrated and shown to exhibit similar performance to comparable cells in planar configurations, demonstrating the feasibility of printing onto complex geometries. Overall, the DIW printing of FeS2 inks is shown to be a viable path toward the making of custom-form conversion lithium batteries. More broadly, ridging is found to optimize rate capability, a finding that may have a broad impact beyond FeS2 and syringe extrusion.
Keywords: 3D printing; custom-form battery; direct ink write; iron disulfide; lithium battery.