  A thick electrode with high areal capacity has been developed as a strategy
for high-energy-density lithium-ion batteries, but thick electrodes have
difficulties in manufacturing and limitations in ion transport. Here, we
reported a new manufacturing approach for ultra-thick electrode with aligned
structure, called structure electrode additive manufacturing or SEAM, which
aligns active materials to the through-thicknesses direction of electrodes
using shear flow and a designed printing path. The ultra-thick electrodes with
high loading of active materials, low tortuous structure, and good structure
stability resulting from a simple and scalable SEAM lead to rapid ion transport
and fast electrolyte infusion, delivering a higher areal capacity than
slurry-casted thick electrodes. SEAM shows strengths in design flexibility and
scalability, which allows the production of practical high energy/power density
structure electrodes.
