For years, battery innovation has focused heavily on chemistry. Companies are chasing long-lasting lithium-ion cells, safe solid-state batteries, and cheaper materials. But a quiet revolution is now gaining momentum, and it could fundamentally change the way batteries are designed, manufactured, and integrated into machines.
Instead of developing what goes inside the battery, a growing number of innovators and researchers are trying to replace the battery itself with 3D printing. The idea is simple but ambitious: create batteries that can fit into almost any shape or structure rather than being limited to conventional cylinder or pouch designs.
3D printed batteries can open up new device designs
The potential applications are significant. Researchers believe that 3D printed batteries can allow manufacturers to fill unused spaces within devices by storing energy, making products lighter, smaller, and more efficient. Smart glasses can hide batteries inside their frames, while drones can use their entire structure to store power instead of relying on separate battery packs.
Another advantage of technology is its flexibility. Unlike most battery efficiencies that depend on a specific chemistry, additive manufacturing techniques can work with lithium-ion, sodium-ion, and solid-state batteries, as well as future energy battery technologies.
Interest in this field is growing rapidly. According to the report, researchers have published nearly 25,000 papers related to 3D printed batteries and battery materials in 2025 alone. However, only a few companies have started testing commercial applications.
Startups target drones, EVs, and military systems
Several startups are now trying to bring this concept from research labs to the real world.
One of them is Material Hybrid Manufacturing, a Miami-based company founded by former Formula One engineer Gabe Elias and battery researcher Christopher Reyes. According to a Wall Street Journal (WSJ) report, the company has developed a custom 3D printing system capable of producing batteries in unusual shapes and configurations.
Material recently received $7.1 million in seed funding and a $1.25 million contract with the US Air Force. The company is developing batteries for Teledyne FLIR’s SkyRaider Drone prototype and says its printed battery method can increase energy storage by 35 percent compared to conventional battery packs that sit in the same space.
Another company, Sakuu, takes a different approach. Instead of printing complete batteries, it aims to improve battery production by eliminating the energy drying ovens used during the production of electrodes. The company says its additive manufacturing process can create battery components without solvents, potentially reducing production costs and energy consumption.
Researchers are also testing solid concepts, including batteries made from simulated moon dust for future lunar bases and structural batteries that are part of a vehicle’s chassis.
While commercial adoption is still years away, experts believe that military and aerospace applications could serve as the first proof of concept. If successful, the technology could eventually find its way into everyday consumer electronics, electric cars, and wearable devices.
