Researchers have developed a 3D printing process that creates custom-shaped batteries to fit irregular spaces in devices. The technique prints anodes, cathodes, separators, and casings without expensive tooling, enabling batteries that conform to spaces like UAV wings or smart glasses frames. A prototype demonstrated 35% better volume utilization and 50% higher energy density compared to standard cylindrical cells in the same space. The process currently requires liquid electrolytes and thin layers of exotic materials, making DIY implementation challenging.
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