Laser direct patterning of battery materials enable a rather new technical approach in order to adjust 3D surface architectures and porosity of composite electrode materials such as LiCoO2, LiMn2O4, LiFePO4, Li(NiMnCo)O2, and Silicon. The architecture design, the increase of active surface area, and the porosity of electrodes or separator layers can be controlled by laser processes and it was shown that a huge impact on electrolyte wetting, lithium-ion diffusion kinetics, cell life-time and cycling stability can be achieved.
In general, the ultrafast laser processing can be used for precise surface texturing of battery materials. Nevertheless, regarding cost-efficient production also nanosecond laser material processing can be successfully applied for selected types of energy storage materials. A new concept for an advanced battery manufacturing including laser materials processing is presented. For developing an optimized 3D architecture for high power composite thick film electrodes electrochemical analytics and post mortem analytics using laser-induced breakdown spectroscopy were performed. Based on mapping of lithium in composite electrodes, an analytical approach for studying chemical degradation in structured and unstructured lithium-ion batteries will be presented.