Among the 3D-printing technologies, fused deposition modeling (FDM) represents a promising route to enable direct incorporation of the battery within the final 3D object. Here, the preparation and characterization of lithium iron phosphate/polylactic acid (LFP/PLA) and SiO₂/PLA 3D-printable filaments, specifically conceived respectively as positive electrode and separator in a lithium-ion battery is reported. By means of plasticizer addition, the active material loading within the positive electrode is raised as high as possible (up to 52 wt.%) while still providing enough flexibility to the filament to be printed. A thorough analysis is performed to determine the thermal, electrical and electrochemical effect of carbon black as conductive additive in the positive electrode and the electrolyte uptake impact of ceramic additives in the separator. Considering both optimized filaments composition and using our previously reported graphite/PLA filament for the negative electrode, assembled and “printed in one-shot” complete LFP/Graphite battery cells are 3D-printed and characterized. Taking advantage of the new design capabilities conferred by 3D-printing, separator patterns and infill density are discussed with a view to enhance the liquid electrolyte impregnation and avoid short-circuits.

Additive manufacturing technologies open the way to the direct-integration of electronics and solid-state battery within the final 3D object. Here, a 3D printable polyethylene oxide/lithium bis(trifluoromethanesulfonyl)imide (PEO/LiTFSI) filament (2.18 × 10⁻³ S cm⁻¹ at 90 °C) optimized to be used as solid polymer electrolyte in a lithium-ion battery is produced to feed a fused deposition modeling (FDM) 3D-printer. Due to its relatively poor mechanical properties compared to classical polymer filament such as polylactic acid (PLA), deep modifications of the 3D-printer were implemented in order to facilitate its printability. The solid polymer electrolyte thermal, structural, morphological, mechanical and electrical characterization is reported. Interestingly, using three different electrochemical impedance spectroscopy sample holders (lateral, sandwich and interdigitated-comb), we demonstrate that conductivity values differs for a same sample, highlighting the PEO chains orientation effect on the conductivity measurements.