The project objective is to develop a reliable and scalable manufacturing process (called afield) that uses acoustic field-assisted assembly of particle-based materials for next-generation…

The project objective is to develop a reliable and scalable manufacturing process (called afield) that uses acoustic field-assisted assembly of particle-based materials for next-generation structured electrodes (SES) for high-energy, high-power, fast charge LI-ION battery packs. Afield uses acoustic waves, and these waves create an acoustic field that can be used to assemble particles in a fluid on a micron-scale. This project is divided into three budget periods (BPS) with distinct objectives to push the TRL of this technology from 2 to 4 by projection completion. BP 1 focuses on scaling up afield from a MM-scale to CM-scale processing system while defining optimal SES for fabrication. BP2 entails refining and further scaling up the initial afield prototype and validating IT for SE battery fabrication while testing an in-situ metrology and inspection workflow to improve process reliability. Lastly, BP 3 concludes the project with a large scale (= 10 AH) modeling analysis of the thermal and electrochemical behavior of afield SES while optimization and further scale-up of the afield chamber for reliable SE processing is conducted with more detailed microstructural and electrochemical characterization. Through BPS 1-3, this project will result in four key outcomes: (1) successful application of acoustic fields to fabricate CM-area SE LI-ION batteries (2) functional cathodes/anodes that demonstrate = 10% (minimum) improvement in capacity or charge behavior over a conventional battery cell, (3) in situ and post situ meteorology and inspection workflows for ensuring reliable SE fabrication, and (4) an in-depth pack-scale analysis of the benefit of SES for electric vehicles (EVS). This novel and disruptive afield process is an example of the manufacturing innovation needed for battery energy storage in the U.S. Because IT will enable large-area, consistent, controllable, and robust manufacturing. This in turn puts U.S. Manufacturers on a path towards a significant reduction in overall battery $/KWH costs.