In-Space/On-Surface 3D Printing of Sodium-Ion Batteries Using In-Situ Resource Utilization Materials (SIBatt-3D)

By leveraging two 3D printing processes (material extrusion and vat photopolymerization), next-generation shape-conformable 3D sodium-ion batteries (SIBs) can be produced, so that dead-volume and weight are minimized. This project is driven by the abundance of SIB primary components in Lunar and Martian regolith (compared to scarce lithium-ion battery materials) and will use materials obtainable from in situ resource utilization (ISRU) through tailored ionic liquid extraction. SIBs provide theoretical faster charge and higher performances compared to lithium-ion batteries. Combined with additive processes for electronics and ceramics, key components and features for batteries such as thermal, electronic, and load management can be embedded - creating compact, conformal, smart batteries.

The first step of this project is dedicated to the formulation and optimization of the 3D printer material feedstocks (inks for material extrusion, and UV photocurable resins for the vat photopolymerization process) while maximizing the amount of ISRU materials. Second step consists in performing the 3D printing of SIB components, followed by subsequent thermal post-processing (optional). Finally, third step of this project is dedicated on the battery assembly and testing through in-depth electrochemical characterization to evaluate the performances.

This innovative project instigates the maturation of in-space manufacturing via 3D printing using in-situ resources. Our team will unveil the most efficient and reliable method for in-space and on-surface shape-conformable SIB printing. This work will be coupled with the use of ISRU through tailored ionic liquid extraction to obtain SIBs materials and precursors. For both routes, adequate printable materials (composite filaments and UV-curable resins) corresponding to each battery component will be printed, post-processed and characterized separately. A full demonstrator will be built containing battery parts and supporting elements. At the end of the 3-year project, the development of shape-conformable SIB components using ISRU materials is envisioned. These results will pave the way toward on-demand in-space and on-surface manufacturing of batteries. This disruptive technology will change the landscape of areas such as portable power for Lunar/Martian construction, sustaining human missions on the Moon/Mars, and robotic and rover miniaturization.

This is early/mid-stage (TRL 5) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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