Laser-based directed energy deposition for micro 3D metallic current collector scaffold for supercapacitor application

Microsupercapacitors (MSCs) are crucial micropower sources due to their rapid charging/discharging and miniatured size. Numerous efforts have been made to develop 3D MSCs, mainly by designing a 3D homogeneous architecture design where active materials are predominantly constructed on an existing current collector. This study successfully fabricates 3D current collector electrodes using laser-based directed energy deposition. A metal current collector with a scaffold of three arrays of 27 high-aspect-ratio (∼14) Inconel 625 micropillars (110 μm diameter) are printed on a stainless-steel substrate, serving as a framework for active material storage. The process is controlled via vision system, enabling the automation in the printing. The metallic current collector is then coated with active electrode materials, resulting in significantly increased capacitance and enhanced electrolyte penetration, highlighting its potential for future applications.