Researchers in Julia R. Greer’s lab at Caltech have developed a new method for creating three-dimensional architected battery cathodes. It has been designed to improve safety, reduce environmental impact, and enhance the performance of future batteries.

The new cathode replaces toxic, expensive, and unethically mined cobalt with lithium iron phosphate (LFP) embedded in a carbon matrix. LFP is much safer and less prone to catching fire or short-circuiting when overcharged.

On its own, LFP isn’t a miracle material; it usually suffers from sluggish performance. But by rethinking the internal architecture of the battery, the team found a loophole.

“We’ve developed a versatile way to make three-dimensional architected battery electrodes from safer materials,” said Yingjin Wang, a graduate student in Greer’s lab. 

“Using lithium iron phosphate, commonly referred to as LFP, combined with a carbon matrix, we eliminated the use of dangerous cobalt while improving the mechanical resilience of the battery,” the first author added. 

3D-architected cathodes

Lithium-ion batteries are the dominant power source for modern mobile devices, electric vehicles, and renewable grids. 

These batteries consist of five core components: an anode (negative electrode), a cathode (positive electrode), a liquid electrolyte to transport ions, a separator to prevent short circuits, and current collectors to harvest electricity. 

While commercially vital, standard designs carry persistent safety risks and performance limitations. To address these flaws, a new development has reimagined battery design, paving the way for less dangerous, more environmentally friendly energy storage that also boosts performance.

Conventional lithium-ion batteries rely on flat, two-dimensional (“planar“) electrodes, but in this new work, the team introduced a three-dimensional, architected cathode produced through 3D printing. 

Moreover, transitioning from a flat design to a 3D-architected battery maximizes the active surface area where chemical energy is converted into electricity.

“We think this is advantageous because you can decouple the solid-state versus liquid-state diffusion distance. The electrolyte is liquid, so as it’s channeling through this architecture, which is like a labyrinth, it has a solid surface available to it anywhere,” Greer explained.

Moreover, the design reduces tortuosity and shortens the physical path that ions must travel between the cathode and separator, thereby increasing the battery’s power density and allowing it to release its stored energy much faster.

Safer alternative

A primary drawback of current lithium-ion batteries is their reliance on cobalt in the cathodes. Cobalt supply chains are plagued by unethical mining practices in remote regions worldwide, and the material itself poses a notable safety hazard due to its tendency to catch fire or short-circuit when overcharged. 

In contrast, lithium iron phosphate is a much safer alternative. Its inherently stable chemical profile makes it far less likely to experience dangerous thermal issues or short circuits.

“LFP by itself is not a new material, but using this additive manufacturing, or 3D-printing, approach to create an architected electrode that doesn’t contain cobalt is a new thing,” Greer said. 

The next major milestone for the researchers is to design a complementary 3D-architected LFP anode, which will create a fully 3D-architected battery that is both energy- and power-dense. 

Achieving this will be a highly complex manufacturing challenge given the early state of the research and the intricate fabrication parameters involved. Ultimately, the team aims to integrate a polymer-based electrolyte to achieve a true solid-state battery.

The study was published in the journal ACS Energy Letters.

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Cambridge researchers have transitioned a laboratory-scale technology into a scalable, real-world application that uses solar power to convert plastic waste and cellulose into clean hydrogen fuel and valuable industrial chemicals.

The team demonstrated a new solar-powered reactor that converts everyday plastic waste, such as fizzy drink bottles, into hydrogen fuel. 

Interestingly, they did it outside, at scale, using a device that can be manufactured with tools not much more complicated than a standard hardware store paint sprayer.

Scaling up the solution for plastic waste

Photoreforming is the process of using solar energy to break down plastic molecules. It is a concept scientists have understood for quite some time, but scaling it up has always been the missing piece of the puzzle.

While the chemistry worked beautifully inside pristine laboratories, it was limited to tiny catalyst plates about the size of a smartphone wrapper. Scaling those up usually meant depending on highly complex manufacturing processes, scorching temperatures, and toxic chemical baths.

“When we started trying to scale this technology up, we quickly found out that what seems simple on a small scale is not simple at all when you’re trying to make it at scale. We can’t really have giant vats of solution to make these panels – it’s just not practical at scale,” said Ariffin Bin Mohamad Annuar, co-first author from Cambridge’s Yusuf Hamied Department of Chemistry. 

To smash through this issue, the researchers went big. And constructed a one-meter-square reactor panel and took it entirely outdoors, testing it under the natural, unpredictable sunlight outside Cambridge’s Department of Chemistry.

The device does not generate electricity like a standard rooftop solar panel. Rather than that, it directly absorbs sunlight to drive a chemical reaction. On one end, it breaks down the polymers in PET plastic bottles and cellulose; on the other, it splits water molecules to harvest pure hydrogen.

The magic coating

The interesting part of the new system lies in how it was built. Compared with earlier versions that required high temperatures and complex liquid-suspension processes, the new solar panels can be assembled at room temperature using basic equipment. 

Professor Dominic Wright’s team developed a specialized molecular precursor material containing cobalt and zirconium. Professor Erwin Reisner’s team then loaded this material into a basic sprayer. 

The light-absorbing catalyst was sprayed directly onto ordinary glass panels at room temperature.

“What surprised me was, after all the optimization, just how simple it is,” said Mohamad Annuar. “We just have this huge panel, we spray our catalyst on it, put it into our solution, put it under the sun, and it produces hydrogen and other valuable chemicals just from plastic waste. It’s just simple and scalable.”

The Cambridge team also provided a comprehensive cost analysis for the system. This economic blueprint is a major first for this type of chemical research, mapping out exactly what it will take to bring the technology the market.

Plus, the manufacturing costs were cut down by using the spray-coating method. It proves that a future of solar-powered, localized recycling hubs is financially viable.

The technology is not quite ready for commercial deployment tomorrow. The team notes that the reactor’s overall durability and conversion efficiency still need refinement before mass production can begin.

However, the researchers have laid down a clear path toward cleaning up the planet by proving that the system can survive the outdoor elements while remaining cheap to produce.

The results are reported in the journal Nature Chemical Engineering on June 24.

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