PrintCap

Next Generation of 3D Printed Structural Supercapacitors

The integration of energy storage functions into load-bearing lightweight structures represents a key innovation approach for future mobile systems. Particularly in unmanned aerial vehicles, the functional coupling of structure and energy storage offers significant potential for reducing overall system weight and installation space. The objective of the PRINTCAP project was the development of an additively manufactured, load-bearing structural supercapacitor system based on continuous, functionalized carbon fibers and thermoplastic PVA gel polymer electrolytes. For this purpose, a continuous process chain was established, ranging from porous carbon-fiber-based electrodes and their modification with vertically aligned carbon nanotubes to continuous tape production and integration into 3D printing (Fig. 1). In addition, numerical multiscale models were developed to couple mechanical and electrochemical requirements and to enable topology-optimized component design. On this basis, an additively manufactured demonstrator was realized, combining structural load-bearing capability and energy storage within a single component. Furthermore, recyclable thermoplastic structures and sustainable electrolyte systems were investigated, establishing a holistic approach to multifunctional, resource-efficient lightweight structures.

Process chain for the fabrication of 3D-printed structural supercapacitors from porous carbon fibers through VACNT-modified electrodes and PVA integration to the additively manufactured demonstrator. — Fig. 1: Integrated manufacturing concept for 3D-printed structural supercapacitors – from porous carbon fibers to highly integrated, material-efficient structures.

Period

01.06.2022–31.05.2025

Project partners

Thales S.A.
NAWAH (ehem. NAWA Technologies)
Leipzig University of Applied Sciences (HTWK Leipzig)

Funding

This project has received funding from the Saxon State Ministry for Science, Culture and Tourism (SMWK) under the M-ERA.NET Call.
Funding code: 100634598