Creating vertical channels is a viable strategy for reducing the tortuosity and improving the charge transfer kinetics of electrodes, hence enhancing the fast-charge capacity of lithium-ion batteries (LIBs) to actualize fast-charging electrical products. Despite the fact that certain published approaches may directly render channels with electrodes without post-treatment, the control of channels’ diameter and edge distance is a challenge that may be exploited to investigate and optimize the relationship between channels and fast-charging electrodes. Moreover, the intricacy of these methods precludes their industrialization and commercialization. From the perspective of industrial and precision control channels, Roll-to-roll (R2R) screen printing is a simple, cost-effective, industrially scalable, and pattern-customizable continuous additive manufacturing approach for producing vertical channels, reducing the tortuosity of electrodes, and improving their fast-charging capabilities. Low-tortuosity electrodes manufactured by screen printing may be utilized to research the relationship between channel architecture and electrochemical performances of electrodes, as well as to boost and broaden mechanism studies and commercial applications.In this work, we first applied screen printing to design and fabricate vertical channels with a high resolution. Channel arrangements, diameters, and edge distances were meticulously developed and illustrated for LIB electrodes in order to maximize their capacity at high current rates. Applying LiNi0.6Mn0.2Co0.2O2 cathode ink, clear patterns were printed on the Aluminum substrate. By comparing and filtering, we revealed that 1) the staggered configuration enhances the high-rate charge capabilities of electrodes and 2) the channel diameter and edge distances decreasing improve the rate performances of electrodes. Specifically, at 4 and 6 C, the optimized electrode possesses a charge capacity that is two- and seven-times greater than the conventional bar-coated electrodes, respectively. In addition, neutron computed tomography demonstrated that the Li of the screen-printed electrodes was homogeneously spread along the channels during the charge and discharge operations. We believe that optimized channels accelerate ion transfer in the vertical direction, promote ion diffusion in the horizontal direction, and maximize transfer kinetics for electrodes. Although more research is required to improve the greatest resolution of screen printing technology and refine the internal design of screen-printed electrodes, R2R screen printing technology offers a new opportunity for the optimization, industrialization, and commercialization of fast-charging LIBs.
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