Research Projects

Rationale and Background:: The rapid growth of microelectronics industry demands safe, affordable high performance all climate operational microbatteries. This project aims to address this need by developing advanced 3D-printed zinc-ion microbatteries (3D-AZIMB) featuring 3D interdigitated electrodes and engineered ‘aqueous based’ electrolyte enabling stable cell operation under extreme climate conditions. Thanks to zinc’s high capacity (820 mAh/g), abundance, and aqueous compatibility, along with 3D-printed interdigitated electrode design advantages, the 3D-AZIMB aim to combine affordability, safety, and sustainability, with high energy and power density. The key to fabricating these 3D microbatteries lies in additive manufacturing (AM). AM enables the creation of customized, layer-by-layer designs, with precise control over the geometry, composition, and structural complexity, making it an ideal solution for next-generation manufacturing processes. However, AM use in energy storage is still nascent.This project aims to push its limits by developing functional inks and integrating advanced nanomaterials (active materials for Zinc ion storage) into AM platform for 3D-AZIMB fabrication. Further, preventing dendrite formation and zinc corrosion/hydrogen evolution in aqueous electrolyte is crucial for practical applications. These problems are even severe at elevated temperatures. For this, the project aims to fabricate ‘water-lean’ electrolyte with improved interfacial and Zn2+ transport characteristics. ::Objectives::  3D printing of active nanomaterials selective towards zinc ion storage as electrodes.  Tuning the Zn2+ solvation structure in aqueous electrolyte to enable efficient ion transport and dendrite free zinc plating across diverse temperature. ::Hypothesis/model to be tested:: The project will develop external stimuli (pH or light, etc.) responsive viscoelastic inks, comprising functional nanomaterials (e.g. graphene, and structurally engineered vanadium/manganese oxides), into AM platforms to create 3D electrodes. Wet-processing techniques will be utilized for their scalability and ability to control microstructure, providing robustness to the 3D printed electrodes. Further, tuning the Zn2+ ion solvation structure and reducing the water activity in aqueous electrolyte plays a significant role to enhance battery life and widen the operating temperature range. To achieve this, we propose a ‘molecular crowded’ electrolyte to tailor the 3D-printed anode/electrolyte interface, enable dendrite-free zinc deposition, and suppress zinc corrosion by disrupting water’s hydrogen bonding. The focus will be on reducing the water electrochemical activity while maintaining facile Zn2+ transport. Infact the electrolyte will be engineered to use the water molecules as lubricant for zinc transport. :: Main experiments to be carried out :: Key fabrication methods for the 3D-AZIMB will include direct ink writing of active electrode materials and template-assisted electrodeposition. In the later technique, graphene-based 3D-printed electrodes will serve as templates, and metallic zinc and active metal oxides (manganese/vanadium oxides) will be electrodeposited onto it. We will focus on external shape control via 3D printing and internal microstructure design through bottom-up assembly. Template methods (e.g. emulsion /ice templating) will be employed to achieve multi-scale control of the electrode architecture. Similarly, the ‘water-lean’ molecularly crowded electrolyte will consist of a zinc salt combined with an anion-rich biopolymer and an antifreezing cosolvent, which acts as a molecular crowding agent to suppress water activity, tailor Zn²⁺ solvation structure, and control Zn²⁺ ion transport, thereby supporting stable cell operation across a broad temperature range. ::Output::  Advanced AM know-how using diverse nanomaterials.  A developed electrolyte recipe for climate-resilient stable zinc batteries.  A prototype 3D-AZIMB.