Additive ManufacturingAM for EnergyAutomotive AMIndustrial Additive ManufacturingSustainability

Sakuu reports 3D printing of functional patterned batteries

First company of record to 3D print fully functional batteries in custom shapes and sizes

Stay up to date with everything that is happening in the wonderful world of AM via our LinkedIn community.

Sakuu Corporation, a transformative additive manufacturing and solid-state battery company, and inventor of the Kavian platform solution for the commercial-scale production of next-generation SwiftPrint batteries and other complex active devices, reported that it has successfully and consistently 3D printed fully functional performant batteries in custom shapes and sizes since December 2022. These batteries were printed as patterned cells containing patterned openings for thermal management, in a fully dry process, at Sakuu’s Silicon Valley battery pilot line facility.

Sakuu is the first company of record to 3D print fully functional patterned batteries in custom shapes and sizes
Sakuu’s factory

“We believe we have the only known solution for manufacturing solid-state batteries at scale with our novel Kavian platform. Collectively, our additive manufacturing and battery teams have accomplished what most thought impossible”

This marks a first-of-its-kind recorded manufacturing achievement and is an important step towards Sakuu’s planned commercial-scale production of next-generation SwiftPrint batteries, including solid-state batteries, from its Kavian platform in gigafactories worldwide.

Karl Littau, Chief Technology Officer at Sakuu commented: “Our development shows that the Kavian™ platform can enable commercial-scale, sustainable production of a wide range of battery technologies from lithium-ion to lithium metal to even solid-state batteries—whereas traditional methods of advanced cell manufacturing continually run into core impediments that prevent mass-scale production. Further, our printing process can allow for substantial gains in energy density for a completed battery. Finally, our platform can customize the form factor of the battery—whereby the battery itself can become part of product design via customized shapes and sizes. This is a profound moment with enormous implications for advanced battery manufacturing.”

Sakuu has invented a fully industrialized process for printing batteries using a proprietary multi-material, multi-layer approach in a parallel and dry process, instead of slow layer-on-layer printing or screen-printing—inherently wet processes that require significant energy to remove unwanted solvents and are susceptible to poor printing quality and unreliable production. The Sakuu invention can deliver low-cost high-speed manufacturing capability coupled with flexibility in shape and form, while also delivering batteries in core categories that matter most to clients and customers alike. For example, Sakuu’s first printed batteries have demonstrated successful cycling performance at C/5, IC current rates, and expectations are to achieve high energy density at 800–1000 Wh/L.

Sakuu is the first company of record to 3D print fully functional patterned batteries in custom shapes and sizes

Utilizing proprietary lithium metal battery chemistry, Sakuu’s printing process starts with raw material and ends with a ready-to-use patterned battery, creating a new paradigm in manufacturing and energy storage. The achievement of patterned battery printing enables a more effective use of battery cell volume with new pathways in thermal dynamic regulation. This allows integration of fixturing, sensors, and thermal transport pathways, as well as regulation through the patterned design—especially when thin sub-cell battery structures are stacked with identical patterned openings for thermal management in alignment.

“We believe we have the only known solution for manufacturing solid-state batteries at scale with our novel Kavian platform. Collectively, our additive manufacturing and battery teams have accomplished what most thought impossible,” said Sakuu Founder and CEO Robert Bagheri. “Printing custom patterned batteries using a dry process that starts with raw material and concludes with a fully functional high-performance battery is a breakthrough that has the potential to transform how batteries of the future are manufactured for all industries. This milestone advances integration between our Kavian platform and our commercial-scale battery production plans towards an energy output goal of 200GWh by 2030 via a network of global partner gigafactories.”

Sakuu’s Kavian platform will be sold to other battery manufacturers as well as leading automotive, e-mobility, and aerospace manufacturers. Those seeking to mass-produce batteries can shorten supply chain and gain key cell performance and safety attributes, as well as inherent material and energy savings, and sustainability benefits for maximum product design innovation. In addition, Sakuu plans on licensing its own battery chemistries, both Li-metal and solid-state, to be produced with either traditional roll-to-roll manufacturing or in gigafactories utilizing Kavian™ manufacturing.

Research
Composites AM 2024

746 composites AM companies individually surveyed and studied. Core composites AM market generated over $785 million in 2023. Market expected to grow to $7.8 billion by 2033 at 25.8% CAGR. This new...

VoxelMatters

VoxelMatters is the online trade media portal published by 3dpbm, a leading marketing and market research firm specializing in the AM industry. 3dpbm also publishes the 3D Printing Business Directory, the AM Focus eBook series and the 3dpbm Research AM Market Reports. 3D Printing Media Network was founded with the goal to provide the latest industry news, insights and opinions to a global audience of professionals and decision makers.

Related Articles

Leave a Reply

Your email address will not be published. Required fields are marked *

Back to top button
Close Popup
Privacy Settings saved!
Privacy Settings

When you visit any web site, it may store or retrieve information on your browser, mostly in the form of cookies. Control your personal Cookie Services here.

These cookies are necessary for the website to function and cannot be switched off in our systems.

Technical Cookies
In order to use this website we use the following technically required cookies
  • PHPSESSID
  • wordpress_test_cookie
  • wordpress_logged_in_
  • wordpress_sec

Decline all Services
Save
Accept all Services

Newsletter

Join our 12,000+ Professional community and get weekly AM industry insights straight to your inbox. Our editor-curated newsletter equips executives, engineers, and end-users with crucial updates, helping you stay ahead.