The Secret Revolution in Battery Technology: 3-D Printing (msn.com)
(Monday June 22, 2026 @11:30PM (EditorDavid)
from the battery-up dept.)
"There's a revolution in battery technology hiding in plain sight," [1]reports The Wall Street Journal . "The 3-D printing of batteries has the potential to put energy storage inside any device.
"This will enable lightweight and long-lasting consumer gadgets, long-range military drones and even nanoscale robots."
> Almost all the innovations we regularly hear about — from cheaper, tougher electric-vehicle batteries to " [2]Holy Grail" solid-state batteries — are about changing the chemistry of batteries. The promise of battery-tech 3-D printing (aka additive manufacturing) is simple: What if batteries could fill any available space, even structural elements of our gadgets, rather than always taking a rigid shape like a pouch or cylinder?
>
> The new approach has obvious appeal. The entire airframe of a drone could be filled with energy storage for increased range. Smartglasses could have sleek battery-packed frames, so they look like everyday eyewear rather than "Revenge of the Nerds" props. One of the biggest advantages of 3-D printing is that it works with any battery, regardless of its cell chemistry. It could advance today's lithium-ion as well as emerging sodium-ion and solid-state tech... Some [startups] are trying to use 3-D printing to create efficiencies in existing battery manufacturing systems. A brave handful of startups are pursuing radical new designs and approaches. They're starting with defense applications, where cost and scale are less of an issue...
>
> At Silicon Valley-based Sakuu... [r]ather than trying to 3-D-print whole batteries, the company is working on replacing one of battery manufacturing's biggest pain points, says Arwed Niestroj, Sakuu's chief operating officer, who is also a nuclear physicist and former head of Mercedes-Benz Research & Development North America. Existing battery assembly lines include football-field-long ovens for drying layers of material that have been dissolved in solvents. This requires a huge amount of energy and is a significant contributor to manufacturing costs, a big reason EV batteries aren't cheaper. Sakuu's process, under development for years, uses additive manufacturing to lay down key battery components without solvents, eliminating the need for ovens, says Niestroj.
>
> Sakuu is currently working to commercialize this tech with a major battery manufacturer...
[1] https://www.msn.com/en-us/money/other/the-secret-revolution-in-battery-technology-3-d-printing/ar-AA263C2k
[2] https://www.wsj.com/business/energy-oil/american-made-battery-76595c0f
"This will enable lightweight and long-lasting consumer gadgets, long-range military drones and even nanoscale robots."
> Almost all the innovations we regularly hear about — from cheaper, tougher electric-vehicle batteries to " [2]Holy Grail" solid-state batteries — are about changing the chemistry of batteries. The promise of battery-tech 3-D printing (aka additive manufacturing) is simple: What if batteries could fill any available space, even structural elements of our gadgets, rather than always taking a rigid shape like a pouch or cylinder?
>
> The new approach has obvious appeal. The entire airframe of a drone could be filled with energy storage for increased range. Smartglasses could have sleek battery-packed frames, so they look like everyday eyewear rather than "Revenge of the Nerds" props. One of the biggest advantages of 3-D printing is that it works with any battery, regardless of its cell chemistry. It could advance today's lithium-ion as well as emerging sodium-ion and solid-state tech... Some [startups] are trying to use 3-D printing to create efficiencies in existing battery manufacturing systems. A brave handful of startups are pursuing radical new designs and approaches. They're starting with defense applications, where cost and scale are less of an issue...
>
> At Silicon Valley-based Sakuu... [r]ather than trying to 3-D-print whole batteries, the company is working on replacing one of battery manufacturing's biggest pain points, says Arwed Niestroj, Sakuu's chief operating officer, who is also a nuclear physicist and former head of Mercedes-Benz Research & Development North America. Existing battery assembly lines include football-field-long ovens for drying layers of material that have been dissolved in solvents. This requires a huge amount of energy and is a significant contributor to manufacturing costs, a big reason EV batteries aren't cheaper. Sakuu's process, under development for years, uses additive manufacturing to lay down key battery components without solvents, eliminating the need for ovens, says Niestroj.
>
> Sakuu is currently working to commercialize this tech with a major battery manufacturer...
[1] https://www.msn.com/en-us/money/other/the-secret-revolution-in-battery-technology-3-d-printing/ar-AA263C2k
[2] https://www.wsj.com/business/energy-oil/american-made-battery-76595c0f