Multi-material, multi-modal 3D printer system for manufacturing energy storage devices, modules, and packs

Abstract

An additive manufacturing system for manufacturing energy storage devices includes a print head having a first nozzle configured to deposit an anode material, a second nozzle configured to deposit a separator material, a third nozzle configured to deposit a cathode material, and a fourth nozzle configured to deposit a casing material. The system further includes a platform configured to receive material from the print head, a drive mechanism configured to move the print head over the platform, and a laser sintering subsystem including laser emitters configured to emit lasers tuned for the anode material, separator material, cathode material, and casing material. The additive manufacturing system also includes a computing system that, to manufacture an energy storage device, executes instructions to selectively iterate between positioning the print head, ejecting material, and activating a laser emitter tuned to sinter the ejected material.

Description

PATENT Attorney Docket No. 157726.8002.W001MULTI-MATERIAL, MULTI-MODAL 3D PRINTER SYSTEM FOR MANUFACTURING ENERGY STORAGE DEVICES, MODULES, AND PACKSBACKGROUND

[0001] Batteries are electrochemical devices that convert chemical energy into electrical energy through redox reactions. A battery typically comprises one or more electrochemical cells, each containing an anode (negative electrode), a cathode (positive electrode), a separator positioned between the electrodes, and an electrolyte that facilitates ion transport between the electrodes. During discharge, chemical reactions at the electrodes generate electrons that flow through an external circuit to power electrical devices. Rechargeable batteries, also known as secondary batteries, can reverse these reactions during charging to restore the stored chemical energy. Various battery chemistries exist, including lithium-ion, nickel-metal hydride, and lead-acid, each offering different characteristics in terms of energy density, power density, cycle life, and operating conditions. Batteries find application across numerous domains, from portable consumer electronics and electric vehicles to grid-scale energy storage systems.BRIEF DESCRIPTION OF THE DRAWINGS

[0002] Reference will now be made, by way of example, to the accompanying drawings which show example embodiments of the present application, and in which:

[0003] Figure 1 is a block diagram of two battery production processes in accordance with various embodiments of the present technology.

[0004] Figure 2 is a block diagram of an additive manufacturing (AM) device for manufacturing energy storage devices in accordance with various embodiments of the present technology.185508251.1PATENT Attorney Docket No. 157726.8002.W001

[0005] Figure 3 is a block diagram of an additive manufacturing (AM) system for manufacturing energy storage devices in accordance with various embodiments of the present technology.

[0006] Figure 4 is a block diagram of an additive manufacturing (AM) system for manufacturing energy storage devices with multiple material nozzles and corresponding calibration, sensor, and sintering components in accordance with various embodiments of the present technology.

[0007] Figure 5 is an exploded view of a 3D printed battery in accordance with various embodiments of the present technology.

[0008] Figure 6 is a flowchart of steps carried out by an additive manufacturing (AM) system when printing a battery in accordance with various embodiments of the present technology.

[0009] Figure 7 is a block diagram of a materials system of an additive manufacturing (AM) system in accordance with various embodiments of the present technology.

[0010] Figure 8 is a block diagram of various modules of an additive manufacturing (AM) system in accordance with various embodiments of the present technology.

[0011] Figure 9 is a flowchart of a process for printing a battery in accordance with various embodiments of the present technology.

[0012] Figure 10 is a block diagram that illustrates an example of a computer system in which at least some operations described herein can be implemented.

[0013] The technologies described herein will become more apparent to those skilled in the art by studying the Detailed Description in conjunction with the drawings. Embodiments or implementations describing aspects of the invention are illustrated by way of example, and the same references can indicate similar elements. While the drawings depict various implementations for the purpose of illustration, those skilled in the art will recognize that alternative implementations can be employed without departing 185508251.1PATENT Attorney Docket No. 157726.8002.W001 from the principles of the present technologies. Accordingly, while specific implementations are shown in the drawings, the technology is amenable to various modifications.DETAILED DESCRIPTION

[0014] The present disclosure pertains to advanced manufacturing for energy storage devices. Specifically, it describes a multi-modal, multi-material 3D printing system designed for fabricating energy storage components such as batteries, supercapacitors, and modular energy systems within a single, streamlined process.

[0015] Traditional energy storage manufacturing involves segmented processes for fabricating components such as electrodes, separators, electrolytes, and casings. These disconnected steps typically include mining raw materials, coating electrode materials onto current collectors, evaporating solvents, calendering to achieve desired thickness and density, slitting electrode sheets, stacking or winding electrode assemblies, packaging cells, welding connections, filling with electrolyte, formation cycling, aging, and final inspection. Each of these steps may be performed using separate equipment, often in different facilities, and may involve multiple handling and transport operations between stages. This fragmented approach can result in increased manufacturing costs, longer production times, and reduced design flexibility.

[0016] The segmented nature of conventional battery manufacturing processes can limit the geometric configurations achievable for energy storage devices. Standard manufacturing techniques tend to produce cells with rectangular or cylindrical form factors, which may not efficiently utilize available space in applications where nonstandard shapes would be advantageous. Applications such as defense systems, Internet of Things (loT) devices, electric vehicles, and wearable electronics may benefit from energy storage devices that conform to irregular or application-specific geometries.

[0017] Additive manufacturing, commonly referred to as three-dimensional (3D) printing, has emerged as a fabrication approach that enables the creation of complex 185508251.1PATENT Attorney Docket No. 157726.8002.W001 geometries through layer-by-layer material deposition. Various 3D printing techniques have been developed for different material types, including polymers, metals, and ceramics. However, the fabrication of functional energy storage devices presents challenges related to the deposition of multiple distinct materials with different properties, the maintenance of material purity during processing, and the achievement of appropriate microstructures for electrochemical performance.

[0018] Energy storage device fabrication may involve materials that are sensitive to atmospheric conditions, including moisture and oxygen. Reactive materials used in battery electrodes may degrade or undergo undesirable chemical reactions when exposed to ambient air during processing. Additionally, achieving desired material properties in deposited layers may involve post-deposition treatments such as thermal processing or sintering.

[0019] Accordingly, the present technology provides for a 3D printing device (also referred to herein as “an additive manufacturing system” or “an additive manufacturing device”) for manufacturing energy storage devices. Across various embodiments, the 3D printing device includes one or more of: (1) A print head with four nozzles that are each configured to deposit a single material type of an energy storage device (e.g., an anode material, a separator material, a cathode material, and a casing material). (2) A platform with a surface to receive material from the print head. (3) A drive mechanism that moves the print head over the surface of the platform. (4) A laser sintering subsystem that includes four lasers that are each tuned to sinter one of the materials types of the four nozzles. (5) Computing hardware (e.g., a processor and memory) that control the print head, nozzles, platform, drive mechanism, and / or the laser sintering subsystem to selectively iterate between (a) positioning the print head over the surface of the platform, (b) ejecting, from the print head toward the surface of the platform, one of the material types from one of the four nozzles, and (c) activating a laser of the laser sintering subsystem that is tuned for the material ejected from the print head to sinter the material.185508251.1PATENT Attorney Docket No. 157726.8002.W001

[0020] The description and associated drawings are illustrative examples and are not to be construed as limiting. This disclosure provides certain details for a thorough understanding and enabling description of these examples. One skilled in the relevant technology will understand, however, that the invention can be practiced without many of these details. Likewise, one skilled in the relevant technology will understand that the invention can include well-known structures or features that are not shown or described in detail, to avoid unnecessarily obscuring the descriptions of examples.Multi-Material, Multi-Modal 3D Printer for Manufacturing Energy Storage Devices, Modules, and Packs

[0021] Figure 1 is a block diagram of two battery production processes. The first production process flow represents a traditional battery production process that includes twelve seguential steps. The first step involves mining, where raw materials are extracted and processed for use in battery components. The second step, coating, involves depositing electrode materials onto current collectors (i.e. , metal materials that collect the current from conductive wiring when the battery is connected to a circuit). The third step, evaporating, removes solvents from the coated electrode materials. The fourth step, calendering, compresses the electrode materials to achieve a desired thickness and density. The fifth step, slitting, cuts the electrode sheets into appropriate dimensions. The sixth step, stacking, arranges the electrode sheets and separators into an electrode assembly. The seventh step, packaging, places the electrode assembly into a cell housing. The eighth step, welding, creates electrical connections between cell components. The ninth step, filling, introduces electrolyte into the cell. The tenth step, formation, involves initial charging and discharging cycles to activate the cell. The eleventh step, aging, allows the cell to stabilize over time. And finally, the twelfth step, final inspection, verifies cell quality and performance.

[0022] The second production process flow represents a streamlined approach using the multi-material, multi-modal 3D printing technology of the present technology. This approach consolidates the second through nineth steps of the traditional process 185508251.1PATENT Attorney Docket No. 157726.8002.W001 into a single printing step, resulting in 5 total steps: mining, printing, formation, aging, and final inspection. Specifically, printing step deposits electrode materials directly in their final configuration, eliminating the need for separate coating, solvent evaporation, and calendering operations. And, the printing step builds the electrode assembly and casing structure layer by layer, obviating the slitting, stacking, packaging, welding, and filling steps that would otherwise be required to assemble discrete components. Though the printing step is described as replacing the second through nineth steps of the traditional process, in some embodiments, the printing step replaces only a subset of those steps. For example, the printing step may replace the send through eighth step and not replace the filling step.

[0023] This approach and its consolidation of the production process has multiple advantages over the traditional production process. For example, this consolidation may reduce manufacturing steps by up to 75% compared to traditional battery manufacturing processes, decrease production time and associated expenses. As another example, the integration of multiple fabrication functions into a single printing step may also reduce the number of parts to construct the energy storage device by combining manufacturing methods and components that would otherwise require separate equipment and handling operations. As an additional example, this approach may reduce material handling between process stages, which may decrease opportunities for contamination or damage to intermediate products.

[0024] Figure 2 is a block diagram of an additive manufacturing (AM) device for manufacturing energy storage devices. In Figure 2, the AM device is shown through multiple views that illustrate the components and configuration of the AM device. The AM device may be configured to fabricate energy storage devices including batteries and supercapacitors. The AM device may fabricate single-cell batteries, multi-cell modules, and multi-module packs within a single platform, enabling integrated manufacturing of energy storage systems at various scales. Applications for the AM device include defense systems, loT devices, and electric vehicles.185508251.1PATENT Attorney Docket No. 157726.8002.W001

[0025] As shown, Figure 2 includes an exploded component assembly 202. The exploded component assembly 202 illustrates the various disassembled parts of the AM device, including a frame structure, mechanical components, and associated hardware arranged in an exploded view configuration. The exploded component assembly 202 shows how various components of the AM device relate to one another prior to assembly.

[0026] Figure 2 also includes a platform view 204 that shows a frame structure with internal components, including a build surface area (i.e., a platform) where material deposition occurs during fabrication. The platform view 204 illustrates the structural framework that supports the printing operations and maintains alignment of the various subsystems. Next, a drive mechanism view 206 depicts a table-like structure with a frame and mechanical elements positioned above that enable movement of the print head relative to the build surface. The drive mechanism view 206 shows the motion system components that position the print head (described further below) during material deposition operations.

[0027] Finally, Figure 2 also includes a device housing view 208 of a sealed (also referred to herein as enclosed) housing with an attached user interface. The device housing view 208 illustrates the external enclosure of the AM device, which may provide environmental isolation during fabrication operations. The AM device may scale from prototyping operations to large-format manufacturing, accommodating different production volumes and energy storage device sizes within the same platform architecture.

[0028] Figure 3 is a block diagram of an AM system 300 (also referred to herein as a “3D printing system 300”) for manufacturing energy storage devices. The 3D printing system 300 may be configured to fabricate energy storage devices through controlled deposition of multiple materials. The 3D printing system 300 includes a print head 302, an extrusion device 304, material 306, an ejection nozzle 308, ejected material 310, a platform 312, a controller 314, a sealed housing 316, a user interface 318, a pump 320, an inlet 322, and an outlet 324.185508251.1PATENT Attorney Docket No. 157726.8002.W001

[0029] The print head 302 contains the extrusion device 304, which receives the material 306 and processes the material 306 for deposition. The extrusion device 304 may control the flow rate and deposition characteristics of the material 306 as the material 306 passes through the print head 302. The print head 302 may contain more than one extrusion device 304 to control the deposition of more than one material type. Such an embodiment is described further with respect to Figure 4 below.

[0030] The 3D printing system 300 includes a drive mechanism (not shown in Figure 3 for simplicity) that positions the print head 302 relative to the platform 312 during fabrication operations. In some embodiments, the drive mechanism of the 3D printing system 300 is the same as the drive mechanism of the drive mechanism view 206 of Figure 2. Across various embodiments, the drive mechanism includes linear actuators, stepper motors, servo motors, or other motion control components that enable precise positioning of the print head 302 along multiple axes. In other embodiments, the drive mechanism moves the print head 302 in a horizontal plane over the surface of the platform 312, allowing the ejection nozzle 308 to deposit material at specified locations. The drive mechanism may also control vertical positioning of the print head 302 to maintain an appropriate distance between the ejection nozzle 308 and the build surface as layers accumulate. In yet further embodiments, the drive mechanism adjusts the angle or position of the ejection nozzle 308 relative to the print head 302. In still further embodiments, the drive mechanism additionally or alternatively moves the platform 312 itself, providing positioning capability through movement of the build surface rather than or in addition to movement of the print head 302 or the ejection nozzle 308. The controller 314 may coordinate operation of the drive mechanism with material deposition from the print head 302 to achieve precise placement of the ejected material 310 according to a predetermined fabrication pattern.

[0031] The material 306 may be one or more of an anode material, cathode material, separator material, casing material, or another material used in energy storage device fabrication. The anode material may include, for example, graphite, silicon, lithium 185508251.1PATENT Attorney Docket No. 157726.8002.W001 titanate, or other materials capable of intercalating or alloying with lithium ions during battery operation. The cathode material may include, for example, lithium cobalt oxide, lithium iron phosphate, lithium nickel manganese cobalt oxide, or other lithium-containing transition metal oxides. The separator material may include, for example, polyethylene, polypropylene, ceramic-coated polymers, or solid electrolyte materials that provide electrical isolation between electrodes while permitting ion transport. The casing material may include, for example, aluminum, stainless steel, polymer composites, or other materials that provide structural support and environmental protection for the internal battery components. The extrusion device 304 feeds the material 306 to the ejection nozzle 308 for controlled deposition.

[0032] The ejection nozzle 308 deposits the ejected material 310 onto the platform 312. The platform 312 serves as a build surface where the ejected material 310 accumulates to form a desired structure of an energy storage device. The platform 312 may be positioned (e.g., via the drive mechanism) relative to the print head 302 to enable layer-by-layer construction of energy storage device components. The ejected material 310 may be deposited in patterns corresponding to the geometry of battery electrodes, separators, or casings.

[0033] The controller 314 manages operations of the 3D printing system 300. The controller 314 is connected to one or more of the print head 302, the extrusion device 304, the platform 312, and the pump 320 (as well as the sensor and laser components described with respect to Figure 4 below) to coordinate the operation of these components during fabrication processes. The controller 314 may control the drive mechanism that moves the print head 302 over a surface of the platform 312, as described with reference to the drive mechanism view 206 of FIG. 2. In some embodiments, the controller 314 may also control a drive mechanism associated with the platform 312 to provide additional positioning capability. The controller 314 may synchronize material deposition with print head positioning to achieve precise placement of the ejected material 310.185508251.1PATENT Attorney Docket No. 157726.8002.W001

[0034] The user interface 318 is connected to the controller 314. The user interface 318 provides an interface for users to input commands, monitor the printing process, and make adjustments as needed. In some embodiments, the user interface 318 displays data associated with the 3D printing system 300, including deposition parameters, environmental conditions, and process status information. In other embodiments, the user interface 318 receives inputs from a user to augment or modify instructions stored in memory associated with the controller 314, enabling manual or automated process adjustments during fabrication operations.

[0035] In some embodiments, the user interface 318 represents a computing device that includes the functions of the controller 314. In other embodiments, the user interface 318 represents a computing device that includes a datastore. In such embodiments, the computing device is capable of storing detailed logs of deposition parameters, environmental conditions, and sensor feedback to the datastore for quality assurance and diagnostic purposes.

[0036] Turning to the enclosure and environmental control of the present technology, the 3D printing system 300 includes the sealed housing 316, the pump 320, the inlet 322, and the outlet 324. The sealed housing 316 encloses at least the print head 302, the extrusion device 304, the material 306, the ejection nozzle 308, and the platform 312 to provide a controlled environment for fabrication operations. The sealed housing 316 isolates the internal components of the 3D printing system 300 from ambient atmospheric conditions during material deposition and processing. This environmental isolation may protect reactive battery materials from exposure to moisture, oxygen, and other atmospheric constituents that could cause degradation or undesirable chemical reactions during fabrication.

[0037] The pump 320 is connected to the sealed housing 316 through the inlet 322. The pump 320 may introduce an inert gas into the sealed housing 316 to establish and maintain an inert atmosphere within the enclosure. Examples of the inert gas include and nitrogen. Argon and nitrogen are chemically unreactive under typical processing 185508251.1PATENT Attorney Docket No. 157726.8002.W001 conditions and may displace oxygen and moisture from the fabrication environment. The use of an inert atmosphere may minimize oxidation and contamination of reactive battery materials, including anode materials and cathode materials that may be sensitive to atmospheric exposure during deposition and sintering operations.

[0038] The outlet 324 provides an exit path from the sealed housing 316, enabling circulation of the atmosphere within the enclosure. The pump 320, the inlet 322, and the outlet 324 form a circulation system that continuously moves the inert gas through the sealed housing 316. This circulation may maintain uniform atmospheric conditions throughout the fabrication volume and may remove particulates, vapors, or other contaminants generated during material deposition or laser sintering operations.

[0039] In some embodiments, the circulation system includes a filter configured to filter the inert gas that exits the sealed housing 316 through the outlet 324. In some embodiments, the filter comprises high-efficiency filtration units that remove particulates and contaminants from the circulating inert gas before the inert gas is reintroduced into the sealed housing 316. The filtration units may maintain a clean, stable environment throughout the fabrication process by capturing airborne particles, material debris, and other contaminants that could otherwise accumulate within the sealed housing 316 or deposit on fabricated components. The combination of inert gas circulation and filtration may enable extended fabrication operations while maintaining atmospheric purity within the sealed housing 316.

[0040] Figure 4 is a block diagram of an AM system 400 (also referred to herein as a 3D printing system 400) for manufacturing energy storage devices with multiple material nozzles and corresponding calibration, sensor, and sintering components. The 3D printing system 400 is further described above with respect to the 3D printing system 300 of Figure 3. As shown in Figure 4, The 3D printing system 400 includes multiple deposition nozzles 402 (as represented by cathode nozzle 402a, separator nozzle 402b, anode nozzle 402c, and battery casing nozzle 402d) that are each associated with one of the leveling and calibration mechanisms 404 (as represented by leveling and 185508251.1PATENT Attorney Docket No. 157726.8002.W001 calibration mechanism 404a, leveling and calibration mechanism 404b, leveling and calibration mechanism 404c, leveling and calibration mechanism 404d) and with sensors 406 (as represented by sensors 406a, sensors 406b, sensors 406c, and sensors 406d). Additionally, the 3D printing system 400 includes ejected material 408, multiple laser emitters 410 (as represented by laser emitter 410a and laser emitter 410b), a platform 412, and additional sensors 414.

[0041] Each of the cathode nozzle 402a, the separator nozzle 402b, the anode nozzle 402c, and the battery casing nozzle 402d is dedicated to depositing a specific battery component material. Though shown with four nozzles associated with four battery components, the present technology is not so limited. Accordingly, the present technology includes embodiments with a single nozzle and a single material, embodiments with three nozzles and three materials, embodiments with ten nozzles and ten materials, and etc. In the embodiment of Figure 4, the cathode nozzle 402a is configured to deposit cathode material, which may include lithium-containing transition metal oxides or other cathode compositions suitable for energy storage applications. The separator nozzle 402b is configured to deposit separator material, which may include polymer-based materials, ceramic materials, or solid electrolyte compositions that provide electrical isolation between electrodes while permitting ion transport. The anode nozzle 402c is configured to deposit anode material, which may include graphite, silicon-based compounds, lithium titanate, or other materials capable of storing lithium ions during battery operation. The battery casing nozzle 402d is configured to deposit casing material, which may include metals, polymers, or composite materials that provide structural support and environmental protection for internal battery components.

[0042] Assigning each nozzle to a single material type, as shown, is expected to reduce cross-contamination between different battery materials during fabrication. By maintaining separate deposition pathways for the cathode material, the separator material, the anode material, and the casing material, the 3D printing system 400 may preserve material purity throughout the fabrication process. This configuration may also 185508251.1PATENT Attorney Docket No. 157726.8002.W001 enable independent optimization of deposition parameters for each material type, as different materials may have different viscosity characteristics, flow rates, and deposition requirements. However, despite these advantages, the present technology is capable of assigning more than one material type to each of the nozzles.

[0043] The deposition nozzles 402 can each be included in a single print head (e.g., the print head 302 of Figure 3). A drive mechanism, such as the drive mechanism described with reference to the drive mechanism view 206 of Figure 2, may position each nozzle over the platform 412 during fabrication operations. The platform 412 (described further above with respect to the platform 312 of Figure 3) serves as a build surface where ejected material 408 accumulates to form the energy storage device structure. The 3D printing system 400 may selectively activate each nozzle according to a predetermined fabrication sequence, depositing layers of casing material, anode material, separator material, and cathode material to construct a complete battery cell or module.

[0044] The leveling and calibration mechanisms 404 enable independent adjustment of each respective nozzle to accommodate differences in material viscosity, flow rate, and deposition characteristics. Each leveling and calibration mechanism 404a, 404b, 404c, 404d may be mechanically coupled to the corresponding nozzle assembly, providing positional adjustment capability along one or more axes. The leveling and calibration mechanism 404a associated with the cathode nozzle 402a may adjust the orientation and height of the cathode nozzle 402a to compensate for variations in cathode material viscosity and flow behavior. Similarly, the leveling and calibration mechanism 404b may adjust the separator nozzle 402b, the leveling and calibration mechanism 404c may adjust the anode nozzle 402c, and the leveling and calibration mechanism 404d may adjust the battery casing nozzle 402d.

[0045] Different battery materials may exhibit different rheological properties that affect deposition behavior. For example, cathode slurries containing lithium-containing transition metal oxides may have different viscosity characteristics compared to anode slurries containing graphite or silicon-based compounds. Separator materials and casing 185508251.1PATENT Attorney Docket No. 157726.8002.W001 materials may similarly exhibit distinct flow rates and deposition characteristics based on their respective compositions. The independent leveling and calibration mechanisms 404 allow each of the deposition nozzles 402 to be adjusted according to the specific properties of the material that the nozzle deposits, rather than requiring a single calibration setting to accommodate all material types.

[0046] The sensors 406 are integrated into each nozzle assembly and continuously monitor deposition quality and alignment. The sensors 406a associated with the cathode nozzle 402a may detect parameters related to the deposition of cathode material, including material flow rate, deposition width, layer thickness, and positional alignment relative to the platform 412. The sensors 406b, the sensors 406c, and the sensors 406d perform analogous monitoring functions for the separator nozzle 402b, the anode nozzle 402c, and the battery casing nozzle 402d, respectively.

[0047] In some embodiments, the sensors 406 include optical sensors, proximity sensors, flow sensors, or other sensing devices capable of generating measurement data during deposition operations. For example, the sensors 406 may detect variations in material flow that indicate changes in material viscosity or nozzle condition. In other embodiments, the sensors 406 monitor the position of the ejected material 408 relative to a target deposition location, enabling detection of alignment deviations.

[0048] The measurement data generated by the sensors 406 enable real-time feedback for independent calibration adjustments during operation. In some embodiments, the controller (e.g., the controller 314 described above with respect to Figure 3) receives the measurement data from the sensors 406 and process the measurement data to determine whether calibration adjustments are warranted. When the measurement data indicates a deviation from target deposition parameters, the controller signals (i) the corresponding leveling and calibration mechanism 404 to adjust the associated nozzle and / or (ii) the drive mechanism to adjust the print head and / or the platform 412. This closed-loop feedback configuration is expected to enable the 3D printing system 400 to maintain deposition quality throughout fabrication operations, 185508251.1PATENT Attorney Docket No. 157726.8002.W001 compensating for variations in material properties, environmental conditions, or component wear that may occur during extended printing sessions.

[0049] As shown in Figure 4, the ejected material 408 is deposited from the deposition nozzles 402 onto the platform 412 during fabrication operations. As each nozzle deposits material onto the platform 412, the ejected material 408 accumulates in layers to form the structure of the energy storage device. The platform 412 receives the ejected material 408 from the cathode nozzle 402a, the separator nozzle 402b, the anode nozzle 402c, and the battery casing nozzle 402d according to a predetermined fabrication sequence controlled by the controller.

[0050] In some embodiments, the 3D printing system 400 includes the laser emitters 410. The laser emitters 410 are configured to perform post-processing sintering of the battery materials after deposition. In some embodiments, the 3D printing system 400 includes as many laser emitters as there are material types deposited by the deposition nozzles 402. For example, in embodiments where four nozzles deposit four distinct material types, the 3D printing system 400 may include four laser emitters, with each laser emitter tuned to the sintering requirements of a corresponding material type. In other embodiments, the number of laser emitters corresponds to the number of nozzles in the print head (e.g., the print head 302 of Figure 3).

[0051] Each of the laser emitters 410 are tuned to specific sintering requirements of the deposited materials. The tuning of each laser emitter may include selection of a laser wavelength, power level, pulse duration, and beam profile characteristics that correspond to the thermal and optical properties of the target material. Different battery materials may require different sintering parameters to achieve desired microstructures and electrical properties. For example, cathode materials containing lithium-containing transition metal oxides may require different laser parameters compared to anode materials containing graphite or silicon-based compounds. The laser emitters may be configured to deliver thermal energy (i.e. , a laser or a laser beam) to the deposited material in a manner that promotes densification, grain growth, or other microstructural changes that enhance the 185508251.1PATENT Attorney Docket No. 157726.8002.W001 electrochemical performance of the fabricated battery components. Accordingly, the laser emitter 410a may be tuned to sinter the anode material deposited from the anode nozzle 402c and the laser emitter 410b may be tuned to sinter the separator material deposited from the separator nozzle 402b.

[0052] In some embodiments, the controller (e.g., the controller 314 described above with respect to Figure 3) coordinates selective activation of the laser emitters 410 based on the type of material deposited and the location of the deposited material on the platform 412. This coordination allows for customized sintering protocols that are tailored to each material type and deposition region. In some embodiments, the controller activates a specific laser emitter immediately after deposition of a corresponding material type, enabling in-situ sintering as the fabrication process proceeds. In other embodiments, the controller activates multiple laser emitters in sequence or simultaneously to achieve uniform sintering across a deposited layer. The selective activation capability enables the 3D printing system 400 to apply different sintering treatments to different regions of the energy storage device structure based on the material composition and geometric requirements of each region.

[0053] In some embodiments, the 3D printing system 400 includes a laser subsystem mount that positions the laser emitters 410 substantially over the surface of the platform 412. The laser subsystem mount may be configured to orient each of the laser emitters 410 toward the deposited material prior to activation, enabling the laser to be pointed at the ejected material 408 on the platform 412 before sintering operations commence. In some embodiments, the laser subsystem mount is a fixed structure that maintains the laser emitters 410 in a stationary position relative to the platform 412, with the laser emitters 410 oriented to cover the build area where material deposition occurs. In other embodiments, the laser subsystem mount includes adjustable positioning elements that allow the orientation of individual laser emitters to be modified based on the location of deposited material. In yet further embodiments, the drive mechanism that moves the print head over the surface of the platform 412 is further configured to move 185508251.1PATENT Attorney Docket No. 157726.8002.W001 the laser sintering subsystem, enabling coordinated positioning of both the deposition nozzles and the laser emitters during fabrication operations. In still further embodiments, the 3D printing system 400 includes a second drive mechanism that is dedicated to moving the laser sintering subsystem over the surface of the platform 412 independently of the print head positioning. Such a configuration may allow the laser emitters 410 to be positioned over specific regions of deposited material while the print head continues deposition operations in other regions, potentially reducing overall fabrication time by enabling concurrent deposition and sintering activities.

[0054] As shown in Figure 4, the 3D printing system 400 includes additional sensors 414. The additional sensors 414 are positioned throughout the sealed housing (e.g., the sealed housing 316 of Figure 3) and / or are integrated into the components (e.g., the platform 412) described above. Accordingly, in some embodiments, the additional sensors 414 are positioned adjacent to the platform 412 to provide deposition and topology verification. In such embodiments, the additional sensors 414 comprise optical sensors or profilometric sensors that are employed to verify the topology of each deposited layer. The optical sensors may include cameras, laser scanners, or other imaging devices that capture visual information about the surface of the ejected material 408. The profilometric sensors may include contact profilometers, optical profilometers, or interferometric sensors that measure surface height variations across the deposited layers.

[0055] Further, in other embodiments, the additional sensors 414 detect variations in layer thickness, surface uniformity, and potential defects in the ejected material 408. Layer thickness variations may indicate inconsistencies in material flow rate, nozzle height, or deposition speed during fabrication. Surface uniformity measurements may reveal regions of uneven material distribution, porosity, or surface roughness that could affect the electrochemical performance of the fabricated battery components. Defect detection may identify voids, cracks, inclusions, or other anomalies that could compromise the structural integrity or electrical properties of the energy storage device.185508251.1PATENT Attorney Docket No. 157726.8002.W001

[0056] In some embodiments, sensors are integrated into the platform 412 to provide additional measurement capability from below the deposited layers. Platform-integrated sensors may include load cells that measure the mass of deposited material, temperature sensors that monitor the thermal state of the build surface, or proximity sensors that detect the presence and position of deposited material.

[0057] In other embodiments, the additional sensors 414 work in conjunction with the sensors 406 to form a sensor system that monitors the fabrication process. Data from the sensor system is processed by the controller (e.g., the controller 314 of Figure 3), which evaluates the measurement data against target parameters for each deposited layer. When the controller detects discrepancies between the measured values and the target parameters, the controller may initiate corrective actions (i.e., through the drive mechanism and / or the levelling and calibration mechanisms 404) to address the detected deviations.

[0058] In some embodiments, the controller adjusts deposition parameters in response to detected discrepancies. Deposition parameter adjustments may include changes to material flow rate, nozzle height, deposition speed, or print head positioning to compensate for detected variations in layer thickness or surface uniformity. In other embodiments, the controller signals the laser emitters to perform corrective sintering operations. Corrective sintering may include additional laser passes over regions where defects or insufficient densification have been detected, or modified laser parameters to address specific material conditions identified by the sensor system. This feedback loop enables the 3D printing system 400 to maintain fabrication quality throughout the manufacturing process by detecting and responding to process variations in real time.

[0059] Figure 5 is an exploded view of a 3D printed battery in accordance with various embodiments of the present technology. As shown, Figure 5 includes a 3D printed battery exploded side view 500a and a 3D printed battery exploded view 500b that both illustrate a layered architecture of an energy storage device fabricated using the 3D printing system (e.g., the 3D printing system 300 or the 3D printing system 400 as 185508251.1PATENT Attorney Docket No. 157726.8002.W001 described above with respect to Figures 3 and 4). The 3D printed battery exploded side view 500a presents the battery components in a linear arrangement from a side perspective, while the 3D printed battery exploded view 500b presents the same components in an isometric exploded configuration that reveals a hexagonal form factor of the battery. The hexagonal geometry demonstrates the capability of the 3D printing process to produce batteries with non-traditional shapes that may conform to available volumes in electrically-powered devices where standard rectangular or cylindrical form factors would not efficiently utilize the available space.

[0060] The 3D printed battery comprises several components arranged in a stacked configuration. An anode 502 appears as a thin electrode layer. A separator 504 is positioned beneath the anode 502 and serves to electrically isolate the electrodes while permitting ion transport between the anode 502 and a cathode 506. The cathode 506 is located below the separator 504 and appears as another thin electrode layer similar in form to the anode 502. An upper casing 508a forms the top enclosure of the battery and features the hexagonal shape with internal structural elements visible in the 3D printed battery exploded view 500b. A lower casing 508b forms the bottom enclosure of the battery and mirrors the hexagonal shape of the upper casing 508a. The upper casing 508a and the lower casing 508b together enclose the anode 502, the separator 504, and the cathode 506 to form the complete battery assembly.

[0061] The layered arrangement of the anode 502, the separator 504, the cathode 506, and the casings 508 may be optimized through the precision deposition capabilities of the 3D printing system described above to enhance energy density (in some instances by up to 300%) compared to conventionally manufactured batteries through optimized material distribution within the available volume. The precision deposition capabilities of the 3D printing system is expected to enable fabrication of the battery components with reduced material waste compared to traditional manufacturing processes that involve subtractive operations such as slitting and trimming. The layer-by-layer construction approach deposits material in the locations where the material is needed for the final 185508251.1PATENT Attorney Docket No. 157726.8002.W001 battery structure, reducing excess material that would otherwise be removed and discarded. The unique material layouts achievable through additive manufacturing allow the battery geometry to be tailored to specific application requirements, taking advantage of irregular or non-standard volumes that may be available in devices such as wearable electronics, loT sensors, or electric vehicle components where space constraints dictate non-traditional battery form factors.

[0062] Figure 6 is a flowchart of steps carried out by an additive manufacturing (AM) system when printing a battery. The steps of Figure 6 can be carried out using a 3D printing system such as the 3D printing system 300 or the 3D printing system 400 described above with respect to Figures 3 and 4.

[0063] At 602 systems power up is initiated (e.g., by the controller 314 of Figure 3) to energize the components of the additive manufacturing device. At 604, the device performs a systems check to verify that the various subsystems including the print head, drive mechanism, laser emitters, and sensors are functioning within operational parameters. At 606, the device preforms a chamber pump down (e.g., via the pump 320 of Figure 3) to evacuate ambient atmosphere from the sealed housing in preparation for establishing a controlled fabrication environment.

[0064] At 608, the device loads the materials to supply the deposition nozzles with the anode material, separator material, cathode material, and casing material (or another material required for the battery). At 610, the device introduces (e.g., via the pump 320) an inert gas such as argon or nitrogen through an inlet of the sealed housing. At 612, the device loads a battery model into a computing device of the device to provide the geometric and material specifications for the battery to be fabricated. At 614, the device checks print conditions to verify that deposition parameters, environmental conditions, and system calibrations are within acceptable ranges for fabrication. At 616, the device commences material deposition.

[0065] At 618, the device deposits the casing material onto the platform via the battery casing nozzle according to the loaded battery model. At 620 the device deposits 185508251.1PATENT Attorney Docket No. 157726.8002.W001 the anode material in the designated regions of the battery structure via the anode nozzle. At 622, the device uses laser emitters to densify - or sinter - the deposited material to achieve desired microstructures and electrical properties of the deposited material.

[0066] At 624, the device deposits the separator material over the anode via the separator nozzle to provide electrical isolation while permitting ion transport. At 626, the device deposits the cathode material over the separator layer via the cathode nozzle. At 628, the device performs an additional densification step to sinter the separator and cathode materials. In some embodiments, the process includes a loop from the step 628 back to the step 618, indicating that the deposition and densification steps may be repeated for building multiple layers or cells within the energy storage device.

[0067] At 630, the device ceases the print operation upon completion of the final deposition and densification cycle. At 632, the device evacuates the sealed housing (also referred to herein as a “chamber”) to remove the inert atmosphere and prepare for device retrieval. At 634, the device performs a final systems check to verify system status and confirm successful completion of the fabrication process. At 636, the battery is unloaded from the platform of the additive manufacturing device.

[0068] Figure 7 is a block diagram of a materials system 700 of an additive manufacturing system (e.g., the 3D printing system 400 of Figure 4). The materials system 700 illustrates the flow of various input materials through a tool head to produce an energy storage device. The material deposition system 700 depicts six material input categories arranged on one side of the diagram: Ink, Slurries, Nano Composites, Pastes, Pellets, and Filaments. Each of these material types represents a different form of feedstock that may be utilized in the fabrication process. The six material inputs feed into a central tool head component, which receives and processes the various materials for deposition. From the tool head, the processed materials are deposited to produce an energy storage device.

[0069] The materials system 700 demonstrates the multi-material capability of the fabrication platform, allowing different material forms to be selectively deposited through 185508251.1PATENT Attorney Docket No. 157726.8002.W001 one or more tool heads to construct energy storage components such as batteries or supercapacitors. This configuration enables the integration of various material types including liquid-based materials such as inks and slurries, composite materials such as nano composites, paste-based materials, and solid feedstocks such as pellets and filaments within a unified manufacturing process. The tool head may receive materials in different physical states and process each material type according to the deposition requirements of the energy storage device being fabricated.

[0070] The materials system 700 provides flexibility in material selection for different battery components. For example, electrode materials may be supplied as slurries or pastes containing active materials suspended in a carrier medium, while casing materials may be supplied as filaments or pellets that are melted and extruded during deposition. The ability to accommodate multiple material forms within a single deposition system may enable fabrication of energy storage devices with diverse material compositions and layer structures, supporting the construction of batteries with tailored electrochemical properties and geometric configurations.

[0071] Figure 8 is a block diagram of various modules of an additive manufacturing (AM) system 800. As shown in Figure 8, the AM system 800 includes a material module 802, a power module 804, a motion module 806, a tool head module 808, a climate controls module 810, a sensors module 812, a CPU module 814, and an AI / ML module 816. Each module performs specific functions that contribute to the overall operation of the additive manufacturing platform.

[0072] The material module 802 manages the various materials used in the 3D printing process. The material module 802 may handle the storage, preparation, and delivery of active battery materials, separators, electrolytes, and casing materials to the print head (e g., the print head 302 of Figure 3). In some embodiments, the material module 802 monitors material levels, controls material feed rates, and maintains material conditions such as temperature and viscosity to support consistent deposition operations. The material module 802 may interface with the material feedstock types described with 185508251.1PATENT Attorney Docket No. 157726.8002.W001 reference to the material deposition system 700 of Figure 7, including inks, slurries, nano composites, pastes, pellets, and filaments.

[0073] The power module 804 provides electrical power to the various components of the system 800. The power module 804 may distribute power to the print head, drive mechanisms, laser emitters, sensors, environmental control systems, and computing components. In some embodiments, the power module 804 includes power conditioning circuitry, voltage regulation, and power distribution networks that deliver appropriate voltage and current levels to each subsystem. The power module 804 may also include backup power capabilities or power monitoring functions that track energy consumption during fabrication operations.

[0074] The motion module 806 controls the movement and positioning of the print head and the platform during fabrication. The motion module 806 may interface with the drive mechanism described with reference to the drive mechanism view 206 of Figure 2 to coordinate positioning of the deposition nozzles relative to the build surface. In some embodiments, the motion module 806 includes motor controllers, position encoders, and motion planning algorithms that enable precise multi-axis movement of the print head over the surface of the platform (e.g., the platform 412 of Figure 4). The motion module 806 may also control vertical positioning to maintain appropriate nozzle-to-surface distances as layers accumulate during the fabrication process.

[0075] The tool head module 808 manages the operation of the multi-material print head, including the individual deposition nozzles and their associated leveling and calibration mechanisms. The tool head module 808 may control the cathode nozzle 402a, the separator nozzle 402b, the anode nozzle 402c, and the battery casing nozzle 402d described with reference to Figure 4. In some embodiments, the tool head module 808 coordinates material extrusion rates, nozzle selection sequences, and calibration adjustments through the leveling and calibration mechanisms 404 of Figure 4. The tool head module 808 may also manage the laser emitters 410 of Figure 4 for post-deposition sintering operations.185508251.1PATENT Attorney Docket No. 157726.8002.W001

[0076] The climate controls module 810 maintains the sealed environment within the system enclosure. The climate controls module 810 may manage the inert atmosphere pump (e.g., the pump 320 of Figure 3), circulation systems, and filtration systems that establish and maintain atmospheric conditions within the sealed housing. In some embodiments, the climate controls module 810 controls the introduction of inert gases such as argon or nitrogen through the an inlet (e.g., the inlet 322 of Figure 3) and monitors atmospheric composition, temperature, and humidity within the fabrication chamber. The climate controls module 810 may also regulate the circulation and filtration of the inert atmosphere to maintain a clean, stable environment throughout the fabrication process.

[0077] The sensors module 812 interfaces with the various sensors throughout the system 800. The sensors module 812 may receive data from the sensors 406 associated with each deposition nozzle, as well as from the additional sensors 414 throughout the housing. In some embodiments, the sensors module 812 aggregates measurement data related to deposition quality, layer topology, material thickness, surface uniformity, and defect detection. The sensors module 812 may process raw sensor signals and transmit formatted measurement data to other modules for analysis and process control decisions.

[0078] The CPU module 814 provides centralized process management for the system 800. The CPU module 814 may synchronize the operation of the print head, laser sintering modules, sensor arrays, and environmental controls through coordination with the other modules. In some embodiments, the CPU module 814 executes fabrication instructions based on loaded battery models, manages timing sequences for material deposition and sintering operations, and processes feedback from the sensors module 812 to implement process adjustments. The CPU module 814 may also handle data logging functions, storing deposition parameters, environmental conditions, and sensor feedback for quality assurance and diagnostic purposes. The CPU module 814 is described further above with respect to the user interface 318 and the controller 314 of Figure 3.185508251.1PATENT Attorney Docket No. 157726.8002.W001

[0079] The AI / ML module 816 provides artificial intelligence and machine learning capabilities to the system 800. The AI / ML module 816 may analyze sensor data from the sensors module 812 to identify patterns, predict process variations, and optimize fabrication parameters. In some embodiments, the AI / ML module 816 implements adaptive process adjustments based on learned relationships between deposition conditions and fabrication outcomes. The AI / ML module 816 may also support predictive maintenance functions by analyzing system performance data to anticipate component wear or calibration drift before such conditions affect fabrication quality.

[0080] Figure 9 is a flowchart of a process 900 for printing a battery in accordance with various embodiments of the present technology. At 902, a drive mechanism of the additive manufacturing device positions a first nozzle over a surface of the platform of the additive manufacturing device. The first nozzle is configured to deposit a casing material of the energy storage device. The drive mechanism may include linear actuators, stepper motors, servo motors, or other motion control components that enable precise positioning of the first nozzle along multiple axes relative to the platform. In some embodiments, the drive mechanism corresponds to the drive mechanism described with reference to the drive mechanism view 206 of Figure 2. The positioning of the first nozzle (as well as the second nozzle, third nozzle, and the fourth nozzle below) can be coordinated by a controller such as the controller 314 of Figure 3, which executes instructions stored in non-transitory memory to control the movement of the print head containing the first nozzle. In some embodiments, the first nozzle corresponds to the battery casing nozzle 402d described with reference to Figure 4.

[0081] At 904, the casing material is ejected from the first nozzle toward the surface of the platform. The ejection of the casing material may be controlled by an extrusion device associated with the first nozzle, such as the extrusion device 304 described with reference to Figure 3. The extrusion device may control the flow rate and deposition characteristics of the casing material as the casing material passes through the first nozzle. In some embodiments, the first nozzle includes a leveling and calibration 185508251.1PATENT Attorney Docket No. 157726.8002.W001 mechanism that adjusts the first nozzle based on a material viscosity, a flow rate, and a deposition characteristic of the casing material. The leveling and calibration mechanism may correspond to the leveling and calibration mechanism 404d described with reference to Figure 4. In some embodiments, the first nozzle further includes a plurality of nozzle sensors that obtain measurement data associated with a quality of the casing material deposition and an alignment of deposition. The nozzle sensors may transmit the measurement data to at least one hardware processor of the additive manufacturing device, and the hardware processor may calibrate the first nozzle based on the measurement data.

[0082] At 906, a first laser emitter of a laser sintering system of the additive manufacturing device is activated. The first laser emitter is tuned to sinter the casing material ejected from the first nozzle with the emission of a first laser. The tuning of the first laser may include selection of laser wavelength, power level, pulse duration, and beam profile characteristics that correspond to the thermal and optical properties of the casing material. In some embodiments, the laser sintering system includes a laser module mount that positions the first laser emitter substantially over the surface of the platform. The laser system mount may be configured to point (i.e., aim or target) the first laser emitter at the casing material ejected from the first nozzle prior to activation of the first laser emitter. In some embodiments, the additive manufacturing device includes an optical sensor and a profilometric sensor that generate measurement data associated with one or more of a material thickness, a material surface uniformity, or a material defect of the casing material. The hardware processor may receive the measurement data and, in response to receiving the measurement data, adjust a deposition parameter of the first nozzle or re-activate the first laser emitter to sinter at least a portion of the casing material.

[0083] At 908, the positioning, ejecting, and activating operations are selectively iterated by the additive manufacturing system for the first nozzle and the first laser emitter as well as additional nozzles and laser emitters that are configured for other material types. For example, the process 900 can include positioning a second nozzle configured 185508251.1PATENT Attorney Docket No. 157726.8002.W001 to deposit an anode material over the surface of the platform using the drive mechanism, ejecting the anode material from the second nozzle toward the surface of the platform, and activating a second laser emitter that is tuned to sinter the anode material. As another example, the process 900 can include positioning a third nozzle configured to deposit a separator material over the surface of the platform, ejecting the separator material from the third nozzle toward the surface of the platform, and activating a third laser that is tuned to sinter the separator material. As a yet further example, the process 900 can include positioning a fourth nozzle configured to deposit a cathode material over the surface of the platform, ejecting the cathode material from the fourth nozzle toward the surface of the platform, and activating a fourth laser that is tuned to sinter the cathode material. In some embodiments, the second nozzle corresponds to the anode nozzle 402c, the third nozzle corresponds to the separator nozzle 402b, and the fourth nozzle corresponds to the cathode nozzle 402a described above with respect to Figure 4.

[0084] In some embodiments, the process 900 is performed within a sealed housing such as the sealed housing 316 of Figure 3. The sealed housing may enclose the print head, the platform, the drive mechanism, and the laser sintering module. A circulation module may pump an inert gas such as argon or nitrogen into the sealed housing such that the inert gas enters the sealed housing through an inlet, and the inert gas may exit the sealed housing through an outlet. A filter may filter the inert gas that exits the sealed housing through the outlet to maintain atmospheric purity within the fabrication environment.

[0085] In other embodiments, the process 900 includes recording, to a datastore of the additive manufacturing device, one or more of a deposition parameter associated with the casing material, the anode material, the separator material, or the cathode material, an environmental condition of the additive manufacturing device, and measurements from one or more sensors of the additive manufacturing device. The recorded data may be used for quality assurance and diagnostic purposes.185508251.1PATENT Attorney Docket No. 157726.8002.W001

[0086] In yet further embodiments, the process 900 includes receiving, at a user interface of the additive manufacturing device, an input from a user. The input may augment or modify instructions stored in memory associated with the controller, enabling manual or automated process adjustments during fabrication operations. For example, the input may modify a target position for one of the nozzles, causing the drive mechanism to position the nozzle at a different location than originally specified in the fabrication instructions.Computer System

[0087] Figure 10 is a block diagram that illustrates an example of a computer system 1000 in which at least some operations described herein can be implemented. As shown, the computer system 1000 can include: one or more processors 1002, main memory 1006, non-volatile memory 1010, a network interface device 1012, a display device 1018, an input / output device 1020, a control device 1022 (e.g., keyboard and pointing device), a drive unit 1024 that includes a machine-readable (storage) medium 1026, and a signal generation device 1030 that are communicatively connected to a bus 1016. The bus 1016 represents one or more physical buses and / or point-to-point connections that are connected by appropriate bridges, adapters, or controllers. Various common components (e.g., cache memory) are omitted from Figure 10 for brevity. Instead, the computer system 1000 is intended to illustrate a hardware device on which components illustrated or described relative to the examples of the figures and any other components described in this specification can be implemented.

[0088] The computer system 1000 can take any suitable physical form. For example, the computer system 1000 can share a similar architecture as that of a server computer, personal computer (PC), tablet computer, mobile telephone, wearable electronic device, network-connected (“smart”) device (e.g., a television or home assistant device), augmented reality / virtual reality (AR / VR) system (e.g., head-mounted display), or any electronic device capable of executing a set of instructions that specify action(s) to be taken by the computer system 1000. In some implementations, the computer system 185508251.1PATENT Attorney Docket No. 157726.8002.W001 1000 can be an embedded computer system, a system-on-chip (SOC), a single-board computer (SBC) system, or a distributed system such as a mesh of computer systems or include one or more cloud components in one or more networks. Where appropriate, one or more computer systems 1000 can perform operations in real time, near real time, or in batch mode.

[0089] The network interface device 1012 enables the computer system 1000 to mediate data in a network 1014 with an entity that is external to the computer system 1000 through any communication protocol supported by the computer system 1000 and the external entity. Examples of the network interface device 1012 include a network adapter card, a wireless network interface card, a router, an access point, a wireless router, a switch, a multilayer switch, a protocol converter, a gateway, a bridge, a bridge router, a hub, a digital media receiver, and / or a repeater, as well as all wireless elements noted herein.

[0090] The memory (e.g., main memory 1006, non-volatile memory 1010, machine-readable medium 1026) can be local, remote, or distributed. Although shown as a single medium, the machine-readable medium 1026 can include multiple media (e.g., a centralized / distributed database and / or associated caches and servers) that store one or more sets of instructions 1028. The machine-readable medium 1026 can include any medium that is capable of storing, encoding, or carrying a set of instructions for execution by the computer system 1000. The machine-readable medium 1026 can be non-transitory or comprise a non-transitory device. In this context, a non-transitory storage medium can include a device that is tangible, meaning that the device has a concrete physical form, although the device can change its physical state. Thus, for example, non-transitory refers to a device remaining tangible despite this change in state.

[0091] Although implementations have been described in the context of fully functioning computing devices, the various examples are capable of being distributed as a program product in a variety of forms. Examples of machine-readable storage media, machine-readable media, or computer-readable media include recordable-type media 185508251.1PATENT Attorney Docket No. 157726.8002.W001 such as volatile and non-volatile memory devices 1010, removable flash memory, hard disk drives, optical disks, and transmission-type media such as digital and analog communication links.

[0092] In general, the routines executed to implement examples herein can be implemented as part of an operating system or a specific application, component, program, object, module, or sequence of instructions (collectively referred to as “computer programs”). The computer programs typically comprise one or more instructions (e.g., instructions 1004, 1008, 1028) set at various times in various memory and storage devices in computing device(s). When read and executed by the processor 1002, the instruction(s) cause the computer system 1000 to perform operations to execute elements involving the various aspects of the disclosure.Remarks

[0093] The terms “example,” “embodiment,” and “implementation” are used interchangeably. For example, references to “one example” or “an example” in the disclosure can be, but not necessarily are, references to the same implementation; and such references mean at least one of the implementations. The appearances of the phrase “in one example” are not necessarily all referring to the same example, nor are separate or alternative examples mutually exclusive of other examples. A feature, structure, or characteristic described in connection with an example can be included in another example of the disclosure. Moreover, various features are described that can be exhibited by some examples and not by others. Similarly, various requirements are described that can be requirements for some examples but not other examples.

[0094] The terminology used herein should be interpreted in its broadest reasonable manner, even though it is being used in conjunction with certain specific examples of the invention. The terms used in the disclosure generally have their ordinary meanings in the relevant technical art, within the context of the disclosure, and in the specific context where each term is used. A recital of alternative language or synonyms does not exclude the use of other synonyms. Special significance should not be placed upon whether or 185508251.1PATENT Attorney Docket No. 157726.8002.W001 not a term is elaborated or discussed herein. The use of highlighting has no influence on the scope and meaning of a term. Further, it will be appreciated that the same thing can be said in more than one way.

[0095] Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense — that is to say, in the sense of “including, but not limited to.” As used herein, the terms “connected,” “coupled,” or any variants thereof mean any connection or coupling, either direct or indirect, between two or more elements; the coupling or connection between the elements can be physical, logical, or a combination thereof. Additionally, the words “herein,” “above,” “below,” and words of similar import can refer to this application as a whole and not to any particular portions of this application. Where context permits, words in the Detailed Description above using the singular or plural number may also include the plural or singular number, respectively. The word “or” in reference to a list of two or more items covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list. The term “module” refers broadly to software components, firmware components, and / or hardware components.

[0096] While specific examples of technology are described above for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. For example, while processes or blocks are presented in a given order, alternative implementations can perform routines having steps, or employ systems having blocks, in a different order, and some processes or blocks may be deleted, moved, added, subdivided, combined, and / or modified to provide alternative or sub-combinations. Each of these processes or blocks can be implemented in a variety of different ways. Also, while processes or blocks are at times shown as being performed in series, these processes or blocks can instead be performed or implemented in parallel, or can be performed at different times. Further, any specific numbers noted185508251.1PATENT Attorney Docket No. 157726.8002.W001 herein are only examples such that alternative implementations can employ differing values or ranges.

[0097] Details of the disclosed implementations can vary considerably in specific implementations while still being encompassed by the disclosed teachings. As noted above, particular terminology used when describing features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the invention with which that terminology is associated. In general, the terms used in the following claims should not be construed to limit the invention to the specific examples disclosed herein, unless the Detailed Description above explicitly defines such terms. Accordingly, the actual scope of the invention encompasses not only the disclosed examples but also all equivalent ways of practicing or implementing the invention under the claims. Some alternative implementations can include additional elements to those implementations described above or include fewer elements.

[0098] Any patents and applications and other references noted above, and any that may be listed in accompanying filing papers, are incorporated herein by reference in their entireties, except for any subject matter disclaimers or disavowals, and except to the extent that the incorporated material is inconsistent with the express disclosure herein, in which case the language in this disclosure controls. Aspects of the invention can be modified to employ the systems, functions, and concepts of the various references described above to provide yet further implementations of the invention.

[0099] To reduce the number of claims, certain implementations are presented below in certain claim forms, but the applicant contemplates various aspects of an invention in other forms. For example, aspects of a claim can be recited in a means-plus-function form or in other forms, such as being embodied in a computer-readable medium. A claim intended to be interpreted as a means-plus-function claim will use the words “means for.” However, the use of the term “for” in any other context is not intended to185508251.1PATENT Attorney Docket No. 157726.8002.W001 invoke a similar interpretation. The applicant reserves the right to pursue such additional claim forms either in this application or in a continuing application.185508251.1

Claims

PATENT Attorney Docket No. 157726.8002.W001 CLAIMS1. An additive manufacturing system for manufacturing energy storage devices, the additive manufacturing system comprising:a print head, the print head including:a first nozzle configured to deposit an anode material of an energy storage device,a second nozzle configured to deposit a separator material of the energy storage device,a third nozzle configured to deposit a cathode material of the energy storage device, anda fourth nozzle configured to deposit a casing material of the energy storage device;a platform, the platform having a surface that is configured to receive material from the print head;a drive mechanism, the drive mechanism configured to move the print head over the surface of the platform;a laser sintering subsystem, the laser sintering subsystem including one or more laser emitters configured to emit:a first laser tuned for the anode material,a second laser tuned for the separator material,a third laser tuned for the cathode material, anda fourth laser tuned for the casing material;at least one hardware processor; andat least one non-transitory memory storing instructions, which, when executed by the at least one hardware processor, selectively iterate between causing the additive manufacturing system to:position, using the drive mechanism, the print head over the surface of the platform;185508251.1PATENT Attorney Docket No. 157726.8002.W001 eject, from the print head toward the surface of the platform, one of the anode material, the separator material, the cathode material, or the casing material; andactivate a laser emitter of the one or more laser emitters that is configured to emit a laser that is tuned for the material ejected from the print head to sinter the material.

2. The additive manufacturing system of claim 1, wherein each of the first nozzle, the second nozzle, the third nozzle, and the fourth nozzle further comprise: a plurality of nozzle sensors that are configured to:obtain measurement data associated with a quality of material deposition and an alignment of deposition, andtransmit the measurement data to the at least one hardware processor, wherein the at least one hardware processor is configured to calibrate each of the first nozzle, the second nozzle, the third nozzle, and the fourth nozzle based on the measurement data.

3. The additive manufacturing system of claim 1, wherein each of the first nozzle, the second nozzle, the third nozzle, and the fourth nozzle further comprise: a levelling and calibration mechanism that is configured to adjust the corresponding nozzle based on a material viscosity, a flow rate, and a deposition characteristic of the material ejected from the print head.

4. The additive manufacturing system of claim 1 , further comprising:an optical sensor and a profilometric sensor that are each configured to generate measurement data associated with one or more of a material thickness, a material surface uniformity, ora material defect of the material ejected from the print head;185508251.1PATENT Attorney Docket No. 157726.8002.W001 the at least one hardware processor further configured to receive the measurement data; andthe at least one non-transitory memory storing instructions, which, when executed by the at least one hardware processor, further cause the additive manufacturing system to:in response to receiving the measurement data - adjust a deposition parameter of the print head, or activate a laser of the laser sintering subsystem that is tuned for the material ejected from the print head.

5. The additive manufacturing system of claim 1 , further comprising:a sealed housing that includes at least the print head, the platform, the drive mechanism, and the laser sintering subsystem; anda circulation module that includes:a pump configured to pump an inert gas into the sealed housing, an inlet through which the inert gas enters the sealed housing, an outlet through which the inert gas exits the sealed housing, and a filter configured to filter the inert gas that exits the sealed housing through the outlet.

6. The additive manufacturing system of claim 5, wherein the inert gas is argon or nitrogen.

7. The additive manufacturing system of claim 1 , further comprising:a user interface, the user interface configured to:display data associated with the additive manufacturing system, and receive, from a user of the additive manufacturing system, an input configured to augment one or more instructions of the at least one non-transitory memory.185508251.1PATENT Attorney Docket No. 157726.8002.W001 8. The additive manufacturing system of claim 1 , wherein the print head further includes:a first extruder that is associated with the first nozzle, the first extruder configured to control the deposition of the anode material through the first nozzle, a second extruder that is associated with the second nozzle, the second extruder configured to control the deposition of the separator material through the second nozzle,a third extruder that is associated with the third nozzle, the third extruder configured to control the deposition of the cathode material through the third nozzle, anda fourth extruder that is associated with the fourth nozzle, the fourth extruder configured to control the deposition of the casing material through the fourth nozzle.

9. The additive manufacturing system of claim 1, wherein the instructions further cause the additive manufacturing system to:record, to a datastore of the additive manufacturing system, one or more of:a deposition parameter associated with the material ejected from the print head;an environmental condition of the additive manufacturing system; and measurements from one or more sensors of the additive manufacturing system.

10. The additive manufacturing system of claim 1 , further comprising:a laser subsystem mount that positions the laser sintering subsystem substantially over the surface of the platform, the laser subsystem mount configured to, prior to activating of the laser, point the laser at the material ejected from the print head.185508251.1PATENT Attorney Docket No. 157726.8002.W00111. A method for manufacturing energy storage devices with an additive manufacturing system, the method comprising:positioning, using a drive mechanism of the additive manufacturing system, a first nozzle of a print head of the additive manufacturing system over a surface of a platform of the additive manufacturing system,wherein the first nozzle is configured to deposit a casing material of an energy storage device;ejecting, from the first nozzle toward the surface of the platform, the casing material;activating a first laser emitter of a laser sintering subsystem of the additive manufacturing system,wherein, when activated, the first laser emitter is configured to emit a first laser that is tuned to sinter the casing material;positioning, using the drive mechanism, a second nozzle of the print head over the surface of the platform,wherein the second nozzle is configured to deposit an anode material of the energy storage device;ejecting, from the second nozzle toward the surface of the platform, the anode material;activating a second laser emitter of the laser sintering subsystem,wherein, when activated, the second laser emitter is configured to emit a second laser that is tuned to sinter the anode material; positioning, using the drive mechanism, a third nozzle of the print head over the surface of the platform,wherein the third nozzle is configured to deposit a separator material of the energy storage device;185508251.1PATENT Attorney Docket No. 157726.8002.W001 ejecting, from the third nozzle toward the surface of the platform, the separator material;activating a third laser emitter of the laser sintering subsystem,wherein, when activated, the third laser emitter is configured to emit a third laser that is tuned to sinter the separator material;positioning, using the drive mechanism, a fourth nozzle of the print head over the surface of the platform,wherein the fourth nozzle is configured to deposit a cathode material of the energy storage device;ejecting, from the fourth nozzle toward the surface of the platform, the cathode material; andactivating a fourth laser emitter of the laser sintering subsystem,wherein, when activated, the fourth laser emitter is configured to emit a fourth laser that is tuned to sinter the cathode material.

12. The method of claim 11 , further comprising:obtaining, via a plurality of nozzle sensors of the first nozzle, measurement data associated with a quality of the casing material deposition and an alignment of deposition; andtransmitting the measurement data to a computing device of the additive manufacturing system,wherein the computing device is configured to calibrate the first nozzle based on the measurement data.

13. The method of claim 11 , further comprising:adjusting the first nozzle, via a levelling and calibration mechanism of the first nozzle, based on a material viscosity, a flow rate, and a deposition characteristic of the casing material.185508251.1PATENT Attorney Docket No. 157726.8002.W001 14. The method of claim 11 , further comprising:subsequent to activating the first laser, generating, via an optical sensor or a profilometric sensor of the additive manufacturing system, measurement data associated with one or more of a material thickness, a material surface uniformity, ora material defect of the casing material; andbased on the measurement data - adjusting a deposition parameter of the first nozzle, orre-activating the first laser to sinter at least a portion of the casing material.

15. The method of claim 11, wherein the additive manufacturing system includes a sealed housing, the method further comprising:pumping an inert gas such that the inert gas - enters the sealed housing through an inlet of the sealed housing, and exits the sealed housing through an outlet of the sealed housing, wherein a filter of the additive manufacturing system filters the inert gas that exits the sealed housing.

16. The method of claim 15, wherein the inert gas is argon or nitrogen.

17. The method of claim 11 , wherein the second nozzle is positioned over the surface of the platform at a first location, the method further comprising:prior to positioning the second nozzle, receiving, at a user interface of the additive manufacturing system, an input; andpositioning, in response to receiving the input, the second nozzle over the surface of the platform at a second location.

18. The method of claim 11 , further comprising:recording, to a datastore of the additive manufacturing system, one or more of:185508251.1PATENT Attorney Docket No. 157726.8002.W001 a deposition parameter associated with one or more of the casing material, the anode material, the separator material, and the cathode material; an environmental condition of the additive manufacturing system; and measurements from one or more sensors of the additive manufacturing system.

19. The method of claim 11 , further comprising:prior to activating the first laser emitter, aiming the first laser emitter towards a portion of the casing material.

20. A three-dimensional (3D) printed battery comprising:a 3D printed anode comprising sintered anode material deposited by a first nozzle of an additive manufacturing system;a 3D printed separator comprising sintered separator material deposited by a second nozzle of the additive manufacturing system;a 3D printed cathode comprising sintered cathode material deposited by a third nozzle of the additive manufacturing system; anda 3D printed casing comprising sintered casing material deposited by a fourth nozzle of the additive manufacturing system,wherein the 3D printed casing encloses the 3D printed anode, the 3D printed separator, and the 3D printed cathode to assemble the 3D printed battery.185508251.1

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