Instantaneous Photonic Sintering Process for Scalable Fabrication of a 3D Garnet Electrolyte Scaffold for Solid-State Batteries

Solid electrolytes enhance lithium-ion battery safety by eliminating solvent leakage risks but face challenges in scalability and energy density for broader commercial applications. This study develops a hybrid solid electrolyte (HSE) combining a gel polymer electrolyte with a 3D porous garnet microstructure to improve battery safety. Photonic sintering (PS) is employed for rapid, selective sintering, allowing the direct application of HSE to substrates and electrodes, enhancing fabrication efficiency. PS prevents particle overgrowth and reduces volatile element loss, offering precise densification control. The fabricated HSE demonstrates notable thermal stability and high ionic conductivity (1.13 S/cm). Pouch-type batteries incorporating the HSE maintain over 99% Coulombic efficiency and similar to 82% capacity retention after 100 cycles at 0.5 C under ambient conditions. This innovative approach represents a significant advancement in solid-state battery manufacturing.