Additive manufacturing of functional high-performance polymers for energy storage, conversion, and insulation systems

TY - JOUR

T1 - Additive manufacturing of functional high-performance polymers for energy storage, conversion, and insulation systems

AU - Chanraksmey, Long

AU - Nie, Bingying

AU - Zhao, Wei

AU - Thummavichai, Kunyapat

AU - Chen, Yu

AU - Chen, Binling

N1 - Publisher Copyright: © 2025 The Authors

PY - 2026/1

Y1 - 2026/1

N2 - Energy-related systems require materials that not only withstand harsh operating conditions, including extreme temperatures, corrosive environments, mechanical stresses, and radiation, but also can be manufactured into complex geometries (e.g. porous networks, patterned membranes, and architected 3D lattices etc.) and integrated structures to deliver specific functionalities such as insulation, separation, membrane operation, energy storage, or shielding. Traditional methods like molding and machining often struggle to create intricate multifunctional components such as porous scaffolds, interdigitated electrodes and layered membranes. In contrast, advances in additive manufacturing (AM) have transformed the production of energy-related components by enabling greater design freedom, rapid prototyping, and the fabrication of customized, high-performance parts with reduced material waste. Among the different classes of AM, high-performance polymers (HPPs) have emerged as promising candidates due to their outstanding thermal, mechanical, and chemical resilience. These, including Polyamide (PA), Polyetherimide (PEI), Polyphenylene Sulfide (PPS), Polysulfone (PSU), Polyetheretherketone (PEEK), and Polyimide (PI), are particularly suited for AM in demanding energy applications. This review summarizes recent advances in the AM of HPPs for electrochemical and thermal energy storage, hydrogen production and storage, oil and gas systems, and radiation shielding. It also examines how structural design and composite reinforcement enhance performance, and outlines current challenges and future research directions to advance AM technologies for energy-related applications.

AB - Energy-related systems require materials that not only withstand harsh operating conditions, including extreme temperatures, corrosive environments, mechanical stresses, and radiation, but also can be manufactured into complex geometries (e.g. porous networks, patterned membranes, and architected 3D lattices etc.) and integrated structures to deliver specific functionalities such as insulation, separation, membrane operation, energy storage, or shielding. Traditional methods like molding and machining often struggle to create intricate multifunctional components such as porous scaffolds, interdigitated electrodes and layered membranes. In contrast, advances in additive manufacturing (AM) have transformed the production of energy-related components by enabling greater design freedom, rapid prototyping, and the fabrication of customized, high-performance parts with reduced material waste. Among the different classes of AM, high-performance polymers (HPPs) have emerged as promising candidates due to their outstanding thermal, mechanical, and chemical resilience. These, including Polyamide (PA), Polyetherimide (PEI), Polyphenylene Sulfide (PPS), Polysulfone (PSU), Polyetheretherketone (PEEK), and Polyimide (PI), are particularly suited for AM in demanding energy applications. This review summarizes recent advances in the AM of HPPs for electrochemical and thermal energy storage, hydrogen production and storage, oil and gas systems, and radiation shielding. It also examines how structural design and composite reinforcement enhance performance, and outlines current challenges and future research directions to advance AM technologies for energy-related applications.

UR - https://www.scopus.com/pages/publications/105024225079

U2 - 10.1016/j.smmf.2025.100121

DO - 10.1016/j.smmf.2025.100121

M3 - Review article

AN - SCOPUS:105024225079

SN - 2772-8102

VL - 4

JO - Smart Materials in Manufacturing

JF - Smart Materials in Manufacturing

M1 - 100121

ER -