Photopolymer-Derived Battery Components: Electrodes, Separators, Current Collectors, Cure Residuals and Cell Qualification

Vat photopolymerization can generate battery electrodes, separators, electrolytes, current-collector architectures and sacrificial precursors with geometric freedom unavailable to planar coating. The enabling resin, however, also introduces a coupled chemical history: photoinitiator fragments, unreacted species, binder or carbonization residue, pore-forming domains and post-processing products can persist at interfaces that control transport and stability. This review defines a qualification architecture for photopolymer-derived battery components. It separates the printed precursor from the final electrochemical state, distinguishes active-material performance from current-collector and separator functions, and requires component evidence to survive assembly into a relevant cell. The central conclusion is non-compensatory: successful printing or attractive half-cell capacity cannot compensate for inadequate ionic transport, unstable interfaces, residual chemistry, unsafe separator behaviour or weak full-cell retention.

ER-265 · Version 0.3.