Additive Manufacturing Technologies for Energy Applications: A Review
Yassar E. Mukhrish, Meshal Alsaiari, Faramarz Djavanroodi, Muhammad Imran, Mushtaq Khan
Abstract. The Additive Manufacturing (AM) pathway creates hierarchical porous structures with pore sizes within the nano to micro scale range supported by greater precision in the making of energy storage devices, providing ion transport and, consequently, shorter diffusion paths. This review focuses on AM technologies such as direct ink writing, stereolithography, and selective laser melting for lithium-ion batteries, sodium-ion batteries, and thermal energy storage systems. Key achievements include fully 3D printed lithium-ion batteries with an areal energy density of 4.45 mAh/cm² and optimized thermal storage with a 57% reduction in solidification time. Critical challenges include formulating inks suitable for printing, multi-scale manufacturing, scale-up, integration of components, and quality standards. The outlook includes computational design optimization, emerging battery chemistries, and 4D printed self-healing systems. Through materials development and process optimization, next-generation AM will change energy storage from standardized to application-specific systems for portable electronics, electric vehicles, and grid-level storage.
Keywords
Additive Manufacturing, 3D Printing, Direct Ink Writing, Energy Storage, Thermal Energy Storage, Batteries, Supercapacitor
Published online 4/25/2026, 7 pages
Copyright © 2026 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Yassar E. Mukhrish, Meshal Alsaiari, Faramarz Djavanroodi, Muhammad Imran, Mushtaq Khan, Additive Manufacturing Technologies for Energy Applications: A Review, Materials Research Proceedings, Vol. 64, pp 739-745, 2026
DOI: https://doi.org/10.21741/9781644904091-92
The article was published as article 92 of the book Energy Futures
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
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