The benefits of 3D printing batteries, from safety to sustainability

Solid-state batteries substitute the fluid electrolyte layer with a solid

The non-flammable solid greatly reduces the risk of fire and explosion, as well as the release of toxic gases via leaks in the existing sulfide-based systems. These batteries use garnet-type solid electrolytes, which provide high ionic conductivity and chemical stability but require temperatures above 1,000 degrees Celsius (1,800 degrees Fahrenheit) for fabrication.

The abundance of raw materials may lead to sodium replacing lithium in batteries

Lower risks of thermal runaway, which can lead to fires and explosions, and less energy capacity loss at low temperatures support the shift. However, sodium's greater weight and lower energy density compared to lithium have made it best suited for stationary storage applications. (Some readers may experience a paywall.)

As of 2022, only about 5% of lithium-ion batteries are recycled globally

Traditional recycling methods have been inadequate for lithium batteries, prompting manufacturers to explore more sustainable battery designs, alongside robotic disassembly and ultrasonic techniques to improve recycling rates. Studies have shown that mining for new lithium requires significantly more water and energy than recycling and results in declining vegetation near mines.

During manufacturing, lithium-ion and alkaline batteries are tested for short-circuiting

Lithium-ion batteries are made by manufacturing anodes, cathodes, and electrolytes via chemical processes, assembling these components into cells, and enclosing multiple interconnected cells within a protective casing. Disposable alkaline battery production involves filling steel containers with preforms—rings of powdered cathode material—paper-based separators, electrolyte solution, and an anode gel.

Genetically modified viruses can help construct battery electrodes

MIT scientists' modifications caused the viruses to attract conductive materials, such as gold ions, which the viruses self-assembled into nanowires that could be used in batteries. These components allow batteries to be thinner and flexible enough to be constructed into new shapes.

3D printing has made musical instruments more accessible

Violins fabricated from durable plastic, rather than being built from wood, can cost hundreds of dollars less, allowing children to try them out without financial pressure. They can be made in colors that appeal to children, sizes tailored to their bodies, and with tactile guides to help visually impaired learners.

Chip-based 3D printers can be pocket-sized and involve no moving parts

Researchers have demonstrated a proof-of-concept version of a chip-based 3D printer that emits visible light onto light-sensitive resin to construct solid shapes. The technology may provide a portable, low-cost solution for future, small-scale fabrication needs.

Massive 3D printers have been used to build homes by stacking layers of 'concrete toothpaste,' a fire-resistant material that effectively insulates against outside noise.

Massive 3D printers have been used to build homes by stacking layers of 'concrete toothpaste,' a fire-resistant material that effectively insulates against outside noise.

In 2015, the FDA approved the first 3D-printed prescription tablet

Spritam, an epilepsy medication, had been too large and difficult to swallow, particularly due to its inability to dissolve easily. The new pill was designed with porous layers to enhance its dissolvability, paving the way for future 3D printing of drugs.

Explore the human and environmental resources needed to make an electric vehicle

The minerals needed to build batteries for electric vehicles are expensive and often take a human toll paid by the communities where they are mined. This interactive article details what minerals make up an electric vehicle battery, where they come from, and dangers posed by the mining process.

Microgravity environments improve the success of 3D bioprinting

Gravity can cause gaps, such as those in the chambers of a 3D-printed heart, to collapse before stem cells, hydrogels, and biochemicals bind together during the bioprinting process. Rather than Earth's surface, some bioprinting is done on the International Space Station, where defective organs are also printed to test treatment methods.

Watch Apple Watch cases be 3D printed from titanium powder

Apple Watch Ultra 3 cases are 3D printed entirely from recycled, aerospace-grade titanium powder using lasers to fuse particles. Over 400 metric tons of raw titanium were saved in 2025, with two watches fabricated from the same amount of raw material that would have previously been used to make one.

How to make your own DIY ionic thruster

In the search for more efficient, sustainable types of propulsive thrust, scientists have dabbled in developing engines using ionic thrust, a type of propulsion using the attractive force of oppositely charged ions. First introduced by a Russian...

As of 2025, most EV batteries retain 95% or more of their range after three years

Data from over 30,000 electric vehicles shows that their batteries are lasting much longer than initially projected, which researchers suggest is due to improved battery management systems and real-world use often being less rigorous than high-performance testing. Cars with 150,000 miles or more that have not had a battery replacement retain at least 83% of their original range.

Most custom earmolds for in-ear hearing aids are made using 3D printing

The technology has also been utilized for behind-the-ear and receiver-in-canal hearing aids, allowing for the creation of structures tailored to the patient's anatomy for enhanced effectiveness. 3D printing has also been used to print retinal eye cells and custom eyeglass frames.

The world's largest lemon battery was made from nearly 3,000 lemons

By connecting lemons with a piece of zinc on one side and a piece of copper on the other, a team from the Royal Society of Chemistry created a fruit battery with a capacity of 2,307.8 volts.

Watch the iterative process of successfully printing a slice of vegan cheesecake

3D printing food requires integrating ingredients with a variety of properties, which may not all resist the physical stress of stacking. This means successful 3D printing of food may require rethinking how ingredients are layered and modifying ratios of each, potentially sacrificing taste for structural integrity.

Sony set the standard for cylinder-shaped batteries when it repurposed manufacturing equipment used to make rolls of magnetic recording tape.

Multi-material 3D printing produces filament waste if only one nozzle is used

When swapping between colors or materials in a fused deposition modeling system, a considerable amount of filament is purged from the nozzle before introducing a new filament. Filament extruders can create new filament from purged elements, but the device combines colors and produces filaments of inconsistent diameter.

More batteries in the power grid would create an on-demand energy reservoir

Most power grids are inefficient because they require enough generation capacity at all times to avoid blackouts. This means at any given time, as much as 50% of generating capacity at power plants can go unused. Batteries would reduce this inefficiency and allow for real-time adjustments.

The 3D-printed rocket maker competing with SpaceX

Producing rockets cheaply and at scale may require atypical manufacturing processes like those developed by Relativity Space, a 3D-printer of rockets. Relativity hopes to not just compete with, but beat, SpaceX in the race to get the first...

Objects can be 3D printed with light by projecting 2D computerized tomography (CT) scans onto rotating cylinders of resin, which solidify upon exposure.

Explore a library of data files for 3D printing

Data files are organized by category, including gadgets, learning, and fashion, with most available in .stl format, which is native to computer-aided design software, and presliced. Some files are also available in .3mf, an open-source file format developed as a universal standard for high-fidelity 3D printing.

Japanese scientists develop an eco-friendly plastic that dissolves in saltwater

The strong and flexible plastic is made from molecules held together by saltwater-sensitive chemical bonds. The components left after the plastic breaks down within hours contain phosphorus and nitrogen, allowing them to serve as soil fertilizer.

Tesla's production of a high-performance electric vehicle revived the EV industry

The Model 3 shifted public perception by showing that EVs could be fast and desirable, and built at scale. However, at one point, Tesla built an entirely manual production line in a tent outside its main factory to keep up with demand.

Artificial coral reefs have been 3D printed from nontoxic, biodegradable terracotta clay, which coral polyps have used as a foundation for rebuilding marine ecosystems.

Lichtenberg figures capture lightning-like patterns within insulators

When high-energy electrons from particle accelerators are fired into materials like acrylic, they form a charged plane before discharging into scarred patterns within the material. By evenly charging a cylindrical bottle through rotation during the irradiation process, a 3D figure of lightning in a bottle can be created.

This is a link to a project that Cincinnati Inc. did on 3d printing a full size, functional Shelby Cobra.

Shelby Cobra ORNL and CI 3D printed a Shelby Cobra vehicle on the BAAM and showcased it at the North America International Auto Show in 2015. Learn more about what we can do for you! Schedule a Consultation

As of 2025, the most cited papers in science include a review of graphene, methods to improve image recognition, streamlining electron density calculations, and optimizing protein studies.

How fusion—which releases energy when two lighter atoms combine to form a heavier atom—differs from fission

See how fireworks are made and learn how metals like magnesium and copper are responsible for different colors.

'Silent' fireworks have gained more interest in recent years as a quieter celebratory option.

Some renewable energy sources may weaken the resiliency of electric grids by removing outage buffers provided by coal- and natural gas-fired plants, which provide the system with more time to find a new power source if a plant goes down.

SpaceX's S-1 or 'prospectus' revealed many previously unknown details about the company, including its unprofitability despite doing $18.7B in revenue in 2025, exactly how many voting shares Elon Musk will have in the company (roughly 85%), and more.

Read a deep dive on the 'all-purpose healing' peptide BPC-157.

An investigation suggests a Scottish island became awash in forever chemicals via seafoam and seaspray—raising questions about what that means for the safety of other coastal areas.

Power lines are dotted with large, brightly colored balls to improve the visibility of these thin wires to helicopters and small planes and help prevent potential crashes.

About 2,000 US babies are born annually without some portion of their limbs, potentially leading to a lifetime of pricey prosthetics.

Studies suggest when you sleep is as important as how much you get, and syncing with your circadian rhythms may lead to less fatigue and improved long-term health outcomes

Indefinite cloning of some endangered species may not sustain their longevity because cloning success rates decrease as genetic mutations accumulate.

Children are now three times more likely to say they want to be a YouTuber when they grow up than an astronaut, with some even attending 'YouTube camps' that teach kids how to create content for the platform.

Pure water does not conduct electricity because this flow of energy requires the movement of charged particles, and water is a neutral molecule.

Some researchers have labeled nomophobia, the fear of being without your phone, as 'the phobia of the 21st century.'

To reduce wrinkles in clothing, research recommends gentle wash cycles with more water and tumble drying with smaller loads and longer times.

Some coin denominations have ridges etched on their sides, partly to prevent counterfeiting, in a practice called 'reeding.'

The 2026 Ebola outbreak in the DRC is spurring new Ebola vaccine development for the Bundibugyo species.

Tattoos remain visible on your skin thanks to immune cells called macrophages

For centuries, Niagara Falls has been a magnet for daredevils seeking to conquer one of nature's most powerful wonders, with its 200-foot drop and water rushing at 32 feet per second with 280 tons of force.

Gerrymandering works through two techniques: cracking opposing voters across districts to dilute their power, and packing them into a few to waste their votes in lopsided majorities.