3D printed batteries may alleviate battery anxiety for your devices.

      For many years, the focus of battery innovation has primarily revolved around chemistry. Companies have aimed for lithium-ion cells with longer lifespans, safer solid-state batteries, and more affordable materials. However, a quieter but significant shift is now underway that could fundamentally alter the design, manufacturing, and integration of batteries in devices.

      A growing number of startups and researchers are working on revolutionizing batteries through 3D printing instead of merely enhancing their internal chemistry. The concept is both straightforward and ambitious: to create batteries that can be shaped to fit nearly any structure rather than being confined to standard cylindrical or pouch forms.

      3D-printed batteries could enable innovative device designs

      The possible applications are vast. Researchers are optimistic that 3D-printed batteries could enable manufacturers to utilize previously unused spaces within devices for energy storage, leading to lighter, thinner, and more efficient products. For instance, smart glasses might incorporate batteries within their frames, while drones could leverage their entire structure for energy storage instead of depending on separate battery packs.

      One notable advantage of this technology is its adaptability. Unlike many advancements in battery technology that hinge on a specific chemical formula, additive manufacturing methods can accommodate lithium-ion, sodium-ion, solid-state batteries, and potentially future battery innovations.

      Interest in this area is rapidly escalating. A report noted that researchers published approximately 25,000 papers on 3D-printed batteries and components in 2025 alone. Nonetheless, only a few companies have started pursuing commercial applications.

      Startups focus on drones, electric vehicles, and military uses

      Several startups are actively working to transition the concept from research environments to practical applications.

      One of these is Material Hybrid Manufacturing, a Miami-based firm founded by former Formula One engineer Gabe Elias and battery researcher Christopher Reyes. A report by the Wall Street Journal (WSJ) states that the company has developed a bespoke 3D-printing system capable of producing batteries in unique shapes and configurations.

      Material has recently secured $7.1 million in seed funding and a $1.25 million contract with the U.S. Air Force. The company is creating prototype batteries for Teledyne FLIR’s SkyRaider drone, claiming that its printed batteries could increase energy storage by as much as 35 percent compared to conventional battery packs of the same size.

      Another company, Sakuu, is pursuing a different route. Rather than printing entire batteries, it seeks to enhance battery production by eliminating energy-intensive drying ovens in the electrode fabrication process. The company asserts that its additive manufacturing method can produce battery components without solvents, which may lower production costs and energy use.

      Researchers are also investigating more unconventional ideas, such as batteries made from simulated lunar dust for potential lunar bases and structural batteries that are integrated into the vehicle frame.

      While widespread commercial adoption may still be a few years away, experts believe that military and aerospace applications could serve as initial testing grounds. If successful, this technology may eventually find its way into everyday consumer electronics, electric vehicles, and wearable technology.