Printed batteries are energy storage devices fabricated using various printing technologies. The process typically involves dispensing conductive inks, electrolyte paste, and separator material onto thin, lightweight substrates.
In flexible electronics, printed batteries serve a critical role because of their ability to integrate seamlessly into designs with flexible forms and shapes. This adaptability allows customization based on specific material and energy requirements.
![](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/webflow/6334888a34bfac03b46aa715/66439aa3568bef3edcabe632_Printed%20Batteries%7C%20Voltera.webp)
![applications](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_128,q_75/voltera/images/applications/materials.webp)
APPLICABLE INDUSTRIES
- Consumer electronics
- Medical equipment
- Automotive
- Aerospace
COMMON SUBSTRATES
- Current collector: Stainless steel, silver, carbon, aluminum, copper, nickel, gold
- Anode: Zinc, silver, carbon, lithium, nickel
- Electrolyte: BMIMTf/PVDF–HFP/ZnTf, H2O/KOH/ZnO, EC:DMC/LiPF6
- Cathode: MnO2, silver, LiCoO2, LiFePO4
COMMON MATERIALS
- Polyethylene terephthalate (PET)
- Polyethylene naphthalate (PEN)
- Polyamide (PI)
- Nylon
- Paper
- Fabric
Market size and driving forces
Although the global printed battery industry is still in its nascent stage, with an estimated value of USD $170.3 million in 2023, it is estimated that by 2030, the size of the printed battery market will reach USD $1.8 billion, demonstrating a compound annual growth rate of 40.12% [1].
Membrane switch market size 2022 to 2023 (USD billion)
![Global printed battery market--](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/voltera/images/applications/global_printed_battery_market.webp)
Source: Global printed battery market size by Maximize Market Research
North America dominates the market share, followed by the Asia Pacific region. The rapid growth in these regions can be attributed to four factors:
- Rising demand for portable health monitoring devices
- Growing adoption of rechargeable IoT applications
- Increasing interest in thinner and lighter consumer electronics
- Advancements in materials science that enable higher energy density
In addition to these factors, as more countries push for a more sustainable economy, research and development in optimizing energy storage of printed batteries is gaining momentum.
Researchers [2] have identified four advantages of printed batteries over competing technologies, namely form-factor freedom, flexibility, cost-effective manufacture, and monolithic integrability.
![Global printed battery market](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_1080,q_75/voltera/images/applications/battery_benefits.webp)
![](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/voltera/images/applications/form_freedoms.webp)
Form-factor freedom
Unlike traditional batteries, which are typically cylindrical or prismatic, printed batteries can be produced in any shape or size. This allows them to be integrated into devices with unconventional architecture. They are ideal for consumer electronics where design freedom is pivotal. For example, a pair of lightweight, egg-shell shaped hand warmers can have a battery custom-printed to distribute weight evenly while optimizing space use.
Form-factor freedom
Unlike traditional batteries, which are typically cylindrical or prismatic, printed batteries can be produced in any shape or size. This allows them to be integrated into devices with unconventional architecture. They are ideal for consumer electronics where design freedom is pivotal. For example, a pair of lightweight, egg-shell shaped hand warmers can have a battery custom-printed to distribute weight evenly while optimizing space use.
![](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/voltera/images/applications/form_freedoms.webp)
![](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/voltera/images/applications/highlight_print_flex.webp)
Flexibility
In applications where bending and flexing are frequent, it is important that device components conform to the contours of the human body or flex along with the materials they are attached to, such as fabrics in smart textiles. The inherent flexibility of printed batteries — made possible by the use of flexible substrates and materials — makes them ideal for wearable medical devices.
Flexibility
In applications where bending and flexing are frequent, it is important that device components conform to the contours of the human body or flex along with the materials they are attached to, such as fabrics in smart textiles. The inherent flexibility of printed batteries — made possible by the use of flexible substrates and materials — makes them ideal for wearable medical devices.
![](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/voltera/images/applications/highlight_print_flex.webp)
![](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/voltera/images/applications/cost_effective.webp)
Cost-effective manufacturing
The printing process for batteries is highly modular and customizable. It is, in theory, scalable, high-throughput, and has a lower unit cost than other methods, such as vacuum-assisted filtration, chemical vapor deposition (CVD), or sputtering [2]. The process allows for the printing of battery components directly from digital files and quick switches between designs without the need for physical retooling. This minimizes the need and costs associated with large inventories.
Cost-effective manufacturing
The printing process for batteries is highly modular and customizable. It is, in theory, scalable, high-throughput, and has a lower unit cost than other methods, such as vacuum-assisted filtration, chemical vapor deposition (CVD), or sputtering [2]. The process allows for the printing of battery components directly from digital files and quick switches between designs without the need for physical retooling. This minimizes the need and costs associated with large inventories.
![](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/voltera/images/applications/cost_effective.webp)
![](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/voltera/images/applications/benefits-monolithic-integrability.webp)
Monolithic integrability
Printed batteries excel in terms of their monolithic integrability — the ability to integrate all components of a battery into a single structure through consecutive printing steps. This integration simplifies the battery construction process, reducing potential points of failure found in traditional battery assembly where components are layered and packaged.
Monolithic integrability
Printed batteries excel in terms of their monolithic integrability — the ability to integrate all components of a battery into a single structure through consecutive printing steps. This integration simplifies the battery construction process, reducing potential points of failure found in traditional battery assembly where components are layered and packaged.
![](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/voltera/images/applications/benefits-monolithic-integrability.webp)
Despite these benefits, a few challenges need to be addressed before the technology can be adopted on a mass scale.
![](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/voltera/images/applications/challenges_durability.webp)
Durability
A major concern is the lifespan of printed batteries. Unlike conventional batteries which are protected by an outer casing, those used in wearable devices can be more susceptible to damage due to their thin design. It is crucial that the batteries are made to be chemically stable and mechanically flexible.
Durability
A major concern is the lifespan of printed batteries. Unlike conventional batteries which are protected by an outer casing, those used in wearable devices can be more susceptible to damage due to their thin design. It is crucial that the batteries are made to be chemically stable and mechanically flexible.
![](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/voltera/images/applications/challenges_durability.webp)
![](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/voltera/images/applications/battery_inks.webp)
Electrochemical performance
Material properties like viscosity and surface tension have a major influence on the printing process. It is important to maintain precise control over the material being dispensed, even at high volume. Researchers and manufacturers need to strike a balance between the electrochemical performance of the materials and their compatibility with the printing technique [3] [4].
Electrochemical performance
Material properties like viscosity and surface tension have a major influence on the printing process. It is important to maintain precise control over the material being dispensed, even at high volume. Researchers and manufacturers need to strike a balance between the electrochemical performance of the materials and their compatibility with the printing technique [3] [4].
![](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/voltera/images/applications/battery_inks.webp)
![Printing a Magnesium Zinc Battery with Saral Inks on PET](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_1200,q_75/webflow/6334888a34bfac03b46aa715/66462bc97fc296fc669185f2_Magnesium%20Zinc%20Battery%20on%20PET.webp)
Printing a Magnesium Zinc Battery with Saral Inks on PET
This project demonstrates printing a functional multilayer magnesium zinc battery onto a flexible PET substrate, using a variety of conductive and insulating inks.
![Batteries](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_128,q_75/voltera/images/applications/brain_heart.webp)
As the printed battery industry evolves, advancements are expected to significantly enhance their performance and expand their applications. In the coming decade, key efforts will likely focus on improving the chemical and mechanical stability of printed batteries to extend their lifespan and enhance their reliability, particularly for use in wearable and flexible electronics.
[1] Maximize Market Research, Global Printed Battery Market: Increasing Demand from the Healthcare Industry to Fuel the Market Growth over the Forecast Period Forecast (2024-2030), 2024.
[2] Benoit Clement, Miaoqiang Lyu, Eeshan Sandeep Kulkarni, Tongen Lin, Yuxiang Hu, Vera Lockett, Chris Greig, Lianzhou Wang, Recent Advances in Printed Thin-Film Batteries, Engineering, Volume 13, 2022, Pages 238-261, ISSN 2095-8099.
[3] C.M. Costa, R. Gonçalves, S. Lanceros-Méndez, Recent advances and future challenges in printed batteries, Energy Storage Materials, Volume 28, 2020, Pages 216-234, ISSN 2405-8297.
[4] Benoit Clement, Miaoqiang Lyu, Eeshan Sandeep Kulkarni, Tongen Lin, Yuxiang Hu, Vera Lockett, Chris Greig, Lianzhou Wang, Recent Advances in Printed Thin-Film Batteries, Engineering, Volume 13, 2022, Pages 238-261, ISSN 2095-8099