Optimization of Photoresin and Processing Conditions for 3D-Printed Pyrolyzed Lattice Electrodes with High Carbon Yield and Electrochemical Performance
Year: 2026
Type: article
Abstract: This work presents a scalable fabrication platform for producing microarchitected carbon lattice electrodes via a gel-infusion and pyrolysis approach. High-resolution 3D-printed acrylate scaffolds were infused with carbon precursor monomers, including acrylonitrile (AN), divinylbenzene (DVB), and bis-ortho-diynylarene (BODA), followed by in situ polymerization and thermal conversion to conductive carbon structures. This method separates scaffold fabrication from precursor incorporation, allowing independent control over structure and material chemistry while overcoming limitations associated with directly printing high-char-yield polymers. The effects of scaffold composition, precursor chemistry, lattice geometry, and processing conditions on key performance metrics, including char yield, electrochemically active surface area (ECSA), electrical resistance, and structural integrity, were systematically investigated. Polyacrylonitrile (PAN)-infused poly(ethylene glycol) diacrylate (PEGDA) scaffolds achieved char yields up to ~41 wt%, significantly exceeding those of commercial photoresins (~5–6 wt%), while polydivinylbenzene (PDVB)- and BODA-infused systems also demonstrated enhanced carbon retention. Optimized pyrolysis conditions, including oxidative stabilization holds, were critical for maximizing carbon yield and minimizing structural shrinkage. Electrochemical characterization revealed that the resulting carbon lattices exhibit measurable capacitance and conductivity, with performance dependent on pyrolysis temperature and resulting surface morphology. PDVB-infused PEGDA structures pyrolyzed to 1000°C achieved ECSA values up to 0.017 cm² g⁻¹, compared to 0.009 for PAN-PEGDA, with further optimization expected to improve performance. Overall, this study establishes a versatile framework for designing 3D-printed carbon electrodes with tunable structure–property relationships and demonstrates the potential of gel-infusion additive manufacturing for advanced energy storage applications.
Source: Stanford Digital Repository
DOI: 10.25740/mr849mq1773
Institution: Stanford University
Language: English
Field: Materials Science
Domain: Physical Sciences
Open Access status: green
OpenAlex ID: W7161302604