b'Synthesizing thin, dense ionSustainable production strategies for solid-state electrolytes improve conductive layers via digitalthe next generation solid-state batteries and electric vehicles.light processing assistedS olid-state electrolytes consisting of inorganic ion conductors are key elements to the performance of solid-state batteries and electric vehicles. electro sinter forging forAmong various solid-state electrolyte material candidates, garnet-based energy storage devices oxides like lithium lanthanum zirconium oxide (LLZO) are promising to achieve higher energy density and improved safety due to their high ion conductivity and chemical stability. Ideally, a high-quality LLZO-based solid-state electrolyte layer should be thin ( 100 m) and dense ( 95% of theoretical density). High temperature (10001200C) and long duration (12-18 h) heat treatment steps are typically required to densify LLZO, which is energy and time consuming. PROJECT NUMBER:In this project, we used INLs advanced manufacturing capabilities to develop three 22A1059-039FP sustainable production strategies for LLZO solid-state electrolyte. In the first strategy, digital light processing, a three-dimensional printing technology, and field assisted TOTAL APPROVED AMOUNT:sintering were combined to reduce the energy consumption when producing thin $694,637 over 2 years and dense LLZO layers. Integrating three-dimensional printing also extended the PRINCIPAL INVESTIGATOR:processing scale of field assisted sintering from millimeters to sub-millimeters. Bor-Rong Chen Furthermore, the time to densify LLZO to 90% was reduced from 12 hours to 10 minutes. For the second strategy, we created 80250 m thick, porous LLZO CO-INVESTIGATORS: scaffolds by treating the three-dimensional printed LLZO layers at 1000C for 10 Arin Preston, INL minutes. The scaffolds were filled with lithium-conductive polymers to create Asa Monson, INL composite SE. The LLZO grains within the scaffold were interconnected, creating Donna Guillen, INL lithium-ion pathways that enhanced conductivity. In the third strategy, our team Jorgen Rufner, INLcollaborated with researchers at The University of Texas, El Paso and developed a Michael Shaltry, INL three-dimensional printing resin that enabled the prints to serve directly as solid Patrick Moo, INL polymer solid-state electrolyte without any further resin removal step or heat COLLABORATOR: treatments at high temperatures. The 100200 m solid-state electrolyte layers were University of Texas, El Pasoflexible due to the polymeric nature, and the LLZO grains blended within improved conductivity and battery performance. 102'