Doctoral Dissertations


Xiaowei Yu

Keywords and Phrases

Additive Manufacturing; Aerosol Printing; Lithium-Ion Batteries; Printed Batteries


“In the pasting decades, considerable efforts have been spent in developing the next-generation lithium-ion batteries (LIBs), from advanced active materials to new manufacturing methods. The development of additive manufacturing (AM) has brought new opportunities to LIBs. In this work, two AM methods are introduced for fabricating electrodes of LIBs. The first method is aerosol printing, which is a solvent-based wet additive method. Whereas the second method is a solvent-free, dry printing method. The commonly used materials for current collectors and active materials (including cathodes and anodes) of LIBs are aerosol printed and the electrochemical functionalities of the printed materials are found to be comparable to those by conventional slurry casting method. Thick electrodes by aerosol printing can deliver an areal capacity which is at least twice of those conventional slurry-casted electrodes. Furthermore, aerosol printing is utilized for the fabrication of customizable LIBs with arbitrary geometry on 3D structures due to its non-planar printing capability. The second AM method, solvent-free dry printing method eliminates the usage of organic solvents and significantly reduces the manufacturing costs. Another advantage of this method is the processability of thick electrodes with tunable porosity. The dry-printed electrodes exhibit much better high-rate performance than conventional slurry-casted electrodes. The dry-printed electrodes with varied porosity are also evaluated in terms of their high-rate performance. Granular models are developed to simulate the interfacial-energy-driven dry powder mixing process. The percolating behavior of the conductive additives during the calendaring process is also studied with the granular models”--Abstract, page iv.


Pan, Heng

Committee Member(s)

Park, Jonghyun
Liou, Frank W.
Chandrashekhara, K.
Kim, Chang-Soo


Mechanical and Aerospace Engineering

Degree Name

Ph. D. in Mechanical Engineering


The author would like to acknowledge the research funding support from Honeywell Federal Manufacturing & Technologies with the U.S. Department of Energy, and the United States Advanced Battery Consortium LLC (USABC).


Missouri University of Science and Technology

Publication Date

Fall 2020

Journal article titles appearing in thesis/dissertation

  • Direct Aerosol Printing of Lithium-Ion Batteries
  • Aerosol Jet Printing of Electrodes for Lithium-Ion Batteries
  • Customizable Nonplanar Printing of Lithium-Ion Batteries
  • Solvent-Free Additive Manufacturing of Electrodes for Lithium-Ion Batteries with Tunable Porosity


xiv, 108 pages

Note about bibliography

Includes bibliographic references.


© 2020 Xiaowei Yu, All rights reserved.

Document Type

Dissertation - Open Access

File Type




Thesis Number

T 11986

Electronic OCLC #


Included in

Manufacturing Commons