3D Printing of Highly Porous Polypropylene Separators for Lithium‐Ion Batteries Using Fused Deposition Modeling and Thermally Induced Phase Separation

Enchinton, Abraham; Martinez, Ana C.; Gonzalez, Katherine R.; Fernandez, Christian A.; Balivada, Sivasai; Merrill, Laura Christine; Cardenas, Jorge Antonio; Panier, Stéphane; Maurel, Alexis

doi:10.1002/admt.202500912

Title: 3D Printing of Highly Porous Polypropylene Separators for Lithium‐Ion Batteries Using Fused Deposition Modeling and Thermally Induced Phase Separation

Journal Article · Thu Sep 04 00:00:00 UTC 2025 · Advanced Materials Technologies

DOI: https://doi.org/10.1002/admt.202500912 · OSTI ID:2997338

Enchinton, Abraham ^[1];

^[1]; Gonzalez, Katherine R. ^[1]; Fernandez, Christian A. ^[1];

^[1];

^[2];

^[3];

^[1]

University of Texas, El Paso, TX (United States)
Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)
Université Picardie Jules Verne, Amiens (France)

Appearing as one of the key-components of lithium-ion batteries (LIBs), this work specifically focuses on the additive manufacturing (AM) of custom-shape separators, facilitated by the filament material extrusion process, also called fused deposition modeling (FDM). The development and optimization of composite thermoplastic filament feedstocks combining polypropylene and paraffin wax, followed by the 3D printing of the separator membranes is shown. A post-processing step, based on thermal induced phase separation (TIPS), is introduced to promote porosity formation through removal of the paraffin wax sacrificial phase within the 3D printed items. Separators with different polypropylene/paraffin wax ratios are developed and the impact on printability, mechanical strength, porosity, and electrochemical performances, is thoroughly discussed. X-ray micro-computed tomography is employed to assess the geometric fidelity and to detect printing defects in a complex 3D lattice structure. The performance of the 3D printed porous separators is also compared to a commercial separator. This pioneering research establishes a foundation for the creation of porous separators that can adapt to and conform into 3D printed battery architectures with novel form factors, and also creates opportunities for the use of FDM and TIPS for a wide range of applications that employ porous structures beyond the energy storage field.

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Research Organization:: Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)

Sponsoring Organization:: National Institutes of Health (NIH); USDOE Laboratory Directed Research and Development (LDRD) Program; USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: NA0003525

OSTI ID:: 2997338

Report Number(s):: SAND--2025-12474J; 1775636

Journal Information:: Advanced Materials Technologies, Journal Name: Advanced Materials Technologies; ISSN 2365-709X

Publisher:: WileyCopyright Statement

Country of Publication:: United States

Language:: English

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Title: 3D Printing of Highly Porous Polypropylene Separators for Lithium‐Ion Batteries Using Fused Deposition Modeling and Thermally Induced Phase Separation

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