Freeform Fabrication of 3D Zinc-Air Batteries and Functional Structural-Electric Assemblies

This paper reports on a fabrication platform and extensions to deposition-based processes that permit freeform fabrication of three-dimensional functional assemblies with embedded conductive wiring and power sources. Structure and joints are produced by fused deposition of thermoplastics and deposition of elastomers. Conductive wiring is achieved by deposition of various low-melting-point alloys and conductive pastes. Batteries based on zinc-air chemistry are produced by deposition of zinc, electrolyte, and catalysts, with separator media and electrodes. Details of the deposition processes are provided and several printed assemblies are demonstrated.