Electrochemical Performance and Characterisation of Chemically Treated Conductive PLA Fused Deposition Modelling (FDM) Current Collectors within Additively Manufactured (3D-Printed) Symmetric Carbon Supercapacitors
Authors: Ferguson Matthew , Egorov Vladimir , Zhang Yan , Gulzar Umair , O'Dwyer Colm 
Published: August 2024

Within the fields of materials science, producing reliable, long-lasting, and efficient energy storage devices to meet the world’s energy needs remains a foremost research goal. 3D-printing (also known as Additive Manufacturing) provides many benefits to this research [1-8], allowing for excellent customization and freedom of design, while eliminating waste material in the manufacturing process. Wearable electronics, medical implants, and the Internet of Things will doubtless benefit from the advantages provided by additive manufacturing.

Our previous work compared the electrochemical performances of symmetric carbon-based supercapacitor devices made using two 3D-printing techniques, SLA (stereolithography) and FDM (fused deposition modelling). Though possessing excellent cycle life, the conductive polylactic acid (PLA) FDM printed current collectors suffered from relatively high resistance and poor cyclic voltammetry curves (far from the rectangular shape of ideal electronic double-layer capacitors). This study aims to improve the conductivity of the FDM current collectors via chemically induced surface modification [9]. Both dimethylformamide (DMF) and aqueous potassium hydroxide (KOH) treatments are used for this purpose. The untreated, DMF-treated, and KOH-treated FDM current collectors are loaded with 1:1 by mass single-walled carbon nanotubes and graphene nanoplatelets carbon slurry, placed within stereolithography (SLA) 3D-printed casings [10], and assembled as supercapacitor cells (separated by glass microfiber filter separators soaked in 6 M aqueous KOH electrolyte).

This works shows how DMF treatment method results in little change in electrochemical performance compared to the untreated FDM current collector cells, but pre-treatment in a solution of KOH identical to the cell electrolyte markedly improves the current collector conductivity. The KOH treatment provides a tenfold decrease in the FDM current collector resistance, which correlates with the improved cyclic voltammetric response. Galvanostatic charge-discharge tests reveal the effect of these treatments on specific capacitance, charge-discharge response, efficiency, and rate capability for these printed cells. The pre-treatment confirms that the cell electrolyte does not limited long term performance by interacting with the PLA current collector in 3D printed supercapacitor cells and tests using other inorganic active materials will also be shown.

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