Currently, portable energy storage devices are lacking in the overall performance characteristics needed to meet desired energy and power density performance demands. Furthermore, these performance demands for long-lasting energy storage devices for portable electronics continue to constantly increase. Batteries remain the main source of portable energy storage, but they generally lack the pulsed-power delivery capability required by many applications, as well as have limited cycle life. Thus, improvements in devices that show a high operational cycle life in addition to delivering high energy and power densities are extremely desirable over a wide range of physical sizes, footprints, and power delivery capabilities. Conventional electrostatic capacitors provide some of these benefits compared to batteries, including high power density and extended cycle life, but are lacking in the energy density capability required to replace batteries in many applications.Electrochemically-based double-layer capacitors (EDLCs) or ultracapacitors offer a promising solution to bridging the gap between maintaining the high-power density capability of electrostatic capacitors while providing a path to improving the energy density to be comparable to batteries –significantly broadening their applicability. An EDLC’s power density and energy density are based on the highly reversible surface charge adsorption-based mechanism of energy storage. This provides benefits in terms of high frequency responses as well as providing a route to supply power for longer duration pulses. Additionally, since the stored capacity is based on the surface charge adsorption-based energy storage, it provides an essentially indefinite lifespan as long as the materials do not degrade. However, current EDLC technologies still provide significantly lower energy density than is available from batteries. This energy density gap must be narrowed if the EDLCs are going to make further inroads toward replacing batteries.The capacitance and energy density are driven by the electrode’s available solution-accessible surface area. Thus, our approach to increasing the energy density of electrochemical capacitors is through the development of carbon nanotube-based electrode structures with a precise, highly controlled and ordered nanostructured porosity. To further improve power and energy density, these electrode structures are used in combination with an ionic liquid electrolyte with high voltage window, thus providing an increased operating voltage. While traditional electrode materials are generally comprised of randomly ordered porous structures, we have developed electrodes with an adjustable and highly controlled pore structure that provide very high surface area. These electrodes are produced using a nanotemplated approach that allows for preparation of high surface area aligned and vertically oriented carbon nanotube (CNT)-based electrodes. The templated approach has the added benefit of a achieving a greater areal CNT density than available in traditional carpet-grown CNT forests as well as providing more uniform and controllable CNT outer and inner diameters. The ability to control these dimensions allows for tailoring the electrode geometry for a specific electrolyte.Ionic liquids are becoming increasingly popular in a variety of applications as a result of their unique properties and highly tailorable chemistry. In electrochemical applications, their large voltage stability window, low vapor pressure, excellent thermal stability at temperatures above most organic solvents’ boiling points, and lower temperature conductivity make them an excellent electrolyte choice. Ionic liquids are ideal for use in higher temperature electronics applications, especially in small-scale microelectronics formats where confined spaces make efficient heat removal very difficult. By making use of ionic liquid electrolytes and optimizing the interaction of the electrolyte with our templated CNT electrodes, we have developed an energy storage technology with high-energy density and high-power density.In this talk, we will discuss the challenges and solutions to scaling up the fabrication and testing of reproducible, nanostructured electrodes from 3.14 cm2 or smaller single-sided lab cells to multiple 200 cm2 electrodes on both sides of an aluminum current collector. We will discuss the electrode fabrication scale-up and performance validation from small coin or disc cells tested in a glove box to larger area sealed pouch cells with integration of an optimized ionic liquid electrolyte. We discuss cell fabrication challenges and solutions including verifying the performance of the electrodes as they are scaled up, and the cell fabrication including ensuring the electrode and separator are reliably wetted with the ionic liquid electrolyte. The challenges of optimizing the practical tradeoff of electrode active depth and minimizing the current collector thickness as we move the electrode and overall cell design to a fully packaged cell while maintaining the optimized electrochemical performance characteristics will be discussed.[DISTRIBUTION STATEMENT A. Approved for public release; Distribution is unlimited 412TW-PA-21154]