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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Rational Design of Pore Size and Functionality in a Series of Isoreticular Zwitterionic Metal–Organic Frameworks

The isoreticular expansion and functionalization of charged-polarized porosity has been systematically explored by the rational design of 11 isostructural zwitterionic metal-organic frameworks (ZW-MOFs). This extended series of general structural composition {[M 3 F(L1) 3 (L2) 1.5 ]·guests} n was prepared by employing the solvothermal reaction of Co and Ni tetrafluoroborates with a binary ligand system composed of zwitterionic pyridinium derivatives and traditional functionalized ditopic carboxylate auxiliary ligands (HL1·Cl = 1-(4-carboxyphenyl)-4,4'-bipyridinium chloride, Hcpb·Cl; or 1-(4-carboxyphenyl-3-hydroxyphenyl)-4,4'-bipyridinium chloride, Hchpb·Cl; and H 2 L2 = benzene-1,4-dicarboxylic acid, H 2 bdc; 2-aminobenzene-1,4-dicarboxylic acid, H 2 abdc; 2,5-dihydroxy-1,4-benzenedicarboxylic acid, H 2 dhbdc; biphenyl-4,4'-dicarboxylic acid, H 2 bpdc; or stilbene-4,4'-dicarboxylic acid, H 2 sdc). Single-crystal structure analyses revealed cubic crystal symmetry ( I -43 m , a = 31-36 Å) with a 3D pore system of significant void space (73-81%). The pore system features three types of pores being systematically tunable in size ranging from 17.4 to 18.8 Å (pore I), 8.2 to 12.8 Å (pore II), and 4.8 to 10.4 Å (pore III) by the choice of auxiliary ligands. All members of this series have noninterpenetrating structures and exhibit robust architectures, as evidenced by their permanent porosity and high thermal stability (up to 300 °C). The structural integrity and specific surface areas could be systematically optimized using supercritical CO 2 exchange methods for framework activation resulting in BET surface areas ranging from 1250 to 2250 m 2 /g. Most interestingly, as a structural landmark, we found the pore surfaces lined with charge gradients employed by the pyridinium ligands. This key feature results in significant adsorption of carbon dioxide and methane which is attributed to polarization effects. With this contribution we pioneer the reticulation of pyridinium building blocks into extended zwitterionic networks in which specific properties can be targeted.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Dictionary Learning with Accumulator Neurons

The Locally Competitive Algorithm (LCA) uses local competition between non-spiking leaky integrator neurons to infer sparse representations, allowing for potentially real-time execution on massively parallel neuromorphic architectures such as Intel's Loihi processor. Here, we focus on the problem of inferring sparse representations from streaming video using dictionaries of spatiotemporal features optimized in an unsupervised manner for sparse reconstruction. Non-spiking LCA has previously been used to achieve unsupervised learning of spatiotemporal dictionaries composed of convolutional kernels from raw, unlabeled video. We demonstrate how unsupervised dictionary learning with spiking LCA (\hbox{S-LCA}) can be efficiently implemented using accumulator neurons, which combine a conventional leaky-integrate-and-fire (\hbox{LIF}) spike generator with an additional state variable that is used to minimize the difference between the integrated input and the spiking output. We demonstrate dictionary learning across a wide range of dynamical regimes, from graded to intermittent spiking, for inferring sparse representations of both static images drawn from the CIFAR database as well as video frames captured from a DVS camera. On a classification task that requires identification of the suite from a deck of cards being rapidly flipped through as viewed by a DVS camera, we find essentially no degradation in performance as the LCA model used to infer sparse spatiotemporal representations migrates from graded to spiking. We conclude that accumulator neurons are likely to provide a powerful enabling component of future neuromorphic hardware for implementing online unsupervised learning of spatiotemporal dictionaries optimized for sparse reconstruction of streaming video from event based DVS cameras.

artificial intelligence↗
DOE OSTI2017

Multi-static Serial LiDAR for Surveillance and Identification of Marine Life at MHK Installations

Final Report for project DE-EE0006787: Multi-static Serial LiDAR for Surveillance and Identification of Marine Life at MHK Installations. This project developed and tested an optical monitoring system prototype that will be suitable for marine and hydrokinetic (MHK) full project lifecycle observation (baseline, commissioning, and decommissioning), with automated real-time classification of marine animals. This system can be deployed to collect pre-installation baseline species observations at a proposed deployment site with minimal post-processing overhead. To satisfy deployed MHK project species of concern (e.g. Endangered Species Act-listed) monitoring requirements, the system provides automated tracking and notification of the presence of managed animals within established perimeters of MHK equipment and provides high resolution imagery of their behavior through a wide range of conditions. During a project’s decommissioning stage, the system can remain installed to provide resource managers with post-installation data. Our technology, known as an Unobtrusive Multi-static Serial LiDAR Imager (UMSLI), is a technology transfer of underwater distributed LiDAR imaging technology that preserves the advantages of traditional optical and acoustic solutions while overcoming associated disadvantages for MHK environmental monitoring applications. This new approach is a purposefully-designed, reconfigurable adaptation of an existing technology that can be easily mounted on or around different classes of MHK equipment. The system uses low average power red (638nm) laser illumination to be invisible and eye-safe to marine animals and is compact and cost effective. The equipment is designed for long term, maintenance-free operations, to inherently generate a sparse primary dataset that only includes detected anomalies (animal presence information), and to allow robust real-time automated animal classification/identification with a low data bandwidth requirement. Advantages of the technology over others currently being used or being considered for MHK monitoring include: Unlike a conventional camera, the depth of field is near-infinite and limited by attenuation (approximately 5-8 m) rather than focal properties of a lens; Operation in an adaptive mode which can project a sparse grid of pulses with higher peak power for longer range detection (>10 meters) and track animals within a zone of interest with high resolution imagery for identification of marine life at closer range (<5m); System detection limit and Signal-to-Noise-Ratio is superior to a camera, due to rejection of both backscattering component and ambient solar background; Multiple wide-angle pulsed laser illuminators and bucket detectors can be flexibly configured to cover a 4pi steradian (i.e. omnidirectional) scene volume, while also retrieving 3D features of animal targets from timing information; Process and classification framework centered around a novel active learning and incremental classification classifier that enables accurate identification of a variety of marine animals automatically; A two-tiered monitoring architecture and invisible watermarking-based data archiving and retrieving approach ensures significant data reduction while preserving high fidelity monitoring. A methodology to train and optimize the classifier for target species of concern to optimize site monitoring effectiveness. This technological innovation addresses a high priority regulatory requirement to observe marine life interaction near MHK projects. Our solution improves resource manager confidence that any interactions between marine animals and equipment are observed in a cost-effective and automated manner. Without EERE funding, this novel application of multi-static LiDAR would not have been available to the MHK community for environmental monitoring.

16 TIDAL AND WAVE POWER↗
DOE OSTI2024

Nanoporous Materials Genome Center Final Technical Report

Nanoporous materials (NPMs), including zeolites/zeotypes, metal-organic frameworks (MOFs), covalent organic frameworks, polymers with intrinsic microporosity, and molecular cages, possess enormous potential in diverse areas relevant to the DOE Office of Science Basic Energy Sciences (BES) mission and objectives. The Nanoporous Materials Genome Center (NMGC) has developed exascale-ready software, computational/theoretical chemistry methods, and data-driven science approaches that enable (i) the de-novo design of functional NPMs for chemical separation and catalysis tasks of increasing complexity, (ii) the discovery of the most promising functional NPMs from databases of synthesized and hypothetical adsorbent structures and the optimization of process conditions for specific applications, and (iii) the microscopic-level understanding of the fundamental interactions underlying the function of NPMs including hierarchical architectures, composite materials, responsive frameworks that may undergo phase transitions or post-synthetic modifications, and materials containing defects, partial disorder, or interfaces. A pivotal part of the NMGC project has been a tight collaboration between leading experimental groups for synthesis and characterization of NPMs and of computational groups that allowed for iterative feedback. The NMGC project has resulted in the publication of more than 290 research and review articles including more than 60 publications in high-impact journals and more than 15 journal covers. NMGC publications have already received more than 20,000 citations (with more than 3,000 citations per year in 2021, 2022, and 2023) and contribute to an h-index of more than 72. The NMGC award has supported collaborative research involving 28 research groups and contributed to the training of more than 40 postdocs, more than 60 graduate students, and more than 20 undergraduate students with broad expertise in data-driven science approaches, computational chemistry methods, and high-performance computing, in addition to the skills to thrive in an integrated experimental and computational research environment.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Modular System for Direct Conversion of Methane into Methanol via Photocatalysis

In this project, the Recipient’s objective is to develop a liquid phase photocatalytic process for direct conversion of methane into methanol. The specific objectives are to: Develop a bifunctional catalyst using a semiconductor photocatalyst architecture to facilitate methane activation to directly convert methane into methanol. Develop a scalable reactor design to maximize mass transfer and methanol selectivity using an optimized photocatalyst. Develop a conceptual process design for a modular system for flare gas utilization. Conduct comprehensive techno-economic and commercial market assessments to position the technology for commercialization.

03 NATURAL GAS↗
DOE OSTI2025

Editorial: Functionalization of porous materials for sustainable energy applications

Global energy demands are shifting toward a more sustainable future, with the goal of achieving carbon neutrality by 2050. Emerging technologies are driving this transition. The industry, academia, government, non-profit organizations, and the broader community are collaboratively working to reduce greenhouse gas (GHG) emissions and address climate change to ensure a sustainable future. According to the International Energy Agency, in 2022, the production, transportation, and processing of oil and gas resulted in 5.1 billion tons of CO 2 -equivalent emissions, representing nearly 15% of all energy-related GHG emissions. Moreover, the end-use of oil and gas accounted for an additional 40% of emissions. The IEA’s Net Zero Emissions by 2050 Scenario calls for immediate, collective action from the industry, transportation and other stakeholders to mitigate these emissions. In this effort, the development of energy materials will play a critical role in reducing emissions. Among these, porous materials offer an innovative solution, leveraging their high surface area, adjustable pore sizes, and chemical versatility to address these pressing challenges effectively. By carefully designing their nanostructures, the architecture and properties of these materials can be tailored for specific applications. Key factors such as chemical composition, particle size, pore distribution, and surface area optimization enhance the reactivity and energy conversion efficiency. Additionally, pre- and post-functionalization processes can introduce targeted chemical properties, further improving their performance. This Research Topic explores recent advancements in energy and materials science through four scholarly papers, showcasing innovative solutions for sustainable energy technologies while providing valuable insights into the unique properties and structure of porous materials (Figure 1). Li et al. present their work on highly defective NiFeV layered triple hydroxides, highlighting enhanced electrocatalytic activity and stability for oxygen evolution reactions (OER). Kovalskii et al. contribute a mini-review on hydrogen storage using hexagonal boron nitride (h-BN) and BN-based materials, offering an insightful overview of these promising materials. Chava et al. discuss their recent achievements in ceramic electrolytes used for improvement of performance of solid-state batteries. Lastly, Li et al. review the properties of porous materials with a focus on shrinkage behavior during the drying process, shedding light on key considerations for material design.

36 MATERIALS SCIENCE↗
NASA NTRS1975

Space station interior design: Results of the NASA/AIA space station interior national design competition

The results of the NASA/AIA space station interior national design competition held during 1971 are presented in order to make available to those who work in the architectural, engineering, and interior design fields the results of this design activity in which the interiors of several space shuttle size modules were designed for optimal habitability. Each design entry also includes a final configuration of all modules into a complete space station. A brief history of the competition is presented with the competition guidelines and constraints. The first place award entry is presented in detail, and specific features from other selected designs are discussed. This is followed by a discussion of how some of these design features might be applied to terrestrial as well as space situations.

Haines, R. F.↗
NASA NTRS1991

Parallel Methods on Large-Scale Structural Analysis and Physics Applications; Symposium, Hampton, VA, Feb. 5, 6, 1991, Selected Papers

Recent advances in parallel methods and algorithms integrated into large-scale codes are presented. Consideration is given to problem decomposition (substructuring), efficient matrix solution algorithms for shared memory architectures, dynamic and transient analysis algorithms for shared memory architectures, and algorithms for distributed and massively parallel architectures. Particular attention is given to partitioning of unstructured problems for parallel processing, parallel-vector computation for linear-structural analysis and nonlinear unconstraint optimization problems, a parallel-vector equation solver for unsymmetric matrices on supercomputers, parallel nonlinear finite element dynamic response, multigrid algorithms for solving structural mechanics problems on supercomputers, structural analysis on massively parallel computers, explicit finite element methods with contact-impact on SIMD computers, and the impact of mapping and sparsity on parallelized finite element method modules.

Storaasli, Olaf O.↗
NASA NTRS1992

Fortran for the nineties

Fortran has largely enjoyed prominence for the past few decades as the computer programming language of choice for numerically intensive scientific, engineering, and process control applications. Fortran's well understood static language syntax has allowed resulting parsers and compiler optimizing technologies to often generate among the most efficient and fastest run-time executables, particularly on high-end scalar and vector supercomputers. Computing architectures and paradigms have changed considerably since the last ANSI/ISO Fortran release in 1978, and while FORTRAN 77 has more than survived, it's aged features provide only partial functionality for today's demanding computing environments. The simple block procedural languages have been necessarily evolving, or giving way, to specialized supercomputing, network resource, and object-oriented paradigms. To address these new computing demands, ANSI has worked for the last 12-years with three international public reviews to deliver Fortran 90. Fortran 90 has superseded and replaced ISO FORTRAN 77 internationally as the sole Fortran standard; while in the US, Fortran 90 is expected to be adopted as the ANSI standard this summer, coexisting with ANSI FORTRAN 77 until at least 1996. The development path and current state of Fortran will be briefly described highlighting the many new Fortran 90 syntactic and semantic additions which support (among others): free form source; array syntax; new control structures; modules and interfaces; pointers; derived data types; dynamic memory; enhanced I/O; operator overloading; data abstraction; user optional arguments; new intrinsics for array, bit manipulation, and system inquiry; and enhanced portability through better generic control of underlying system arithmetic models. Examples from dynamical astronomy, signal and image processing will attempt to illustrate Fortran 90's applicability to today's general scalar, vector, and parallel scientific and engineering requirements and object oriented programming paradigms. Time permitting, current work proceeding on the future development of Fortran 2000 and collateral standards will be introduced.

Himer, J. T.↗
NASA NTRS1994

Evaluation of NASA's end-to-end data systems using DSDS+

The Data Systems Dynamic Simulator (DSDS+) is a software tool being developed by the authors to evaluate candidate architectures for NASA's end-to-end data systems. Via modeling and simulation, we are able to quickly predict the performance characteristics of each architecture, to evaluate 'what-if' scenarios, and to perform sensitivity analyses. As such, we are using modeling and simulation to help NASA select the optimal system configuration, and to quantify the performance characteristics of this system prior to its delivery. This paper is divided into the following six sections: (1) The role of modeling and simulation in the systems engineering process. In this section, we briefly describe the different types of results obtained by modeling each phase of the systems engineering life cycle, from concept definition through operations and maintenance; (2) Recent applications of DSDS+. In this section, we describe ongoing applications of DSDS+ in support of the Earth Observing System (EOS), and we present some of the simulation results generated of candidate system designs. So far, we have modeled individual EOS subsystems (e.g. the Solid State Recorders used onboard the spacecraft), and we have also developed an integrated model of the EOS end-to-end data processing and data communications systems (from the payloads onboard to the principle investigator facilities on the ground); (3) Overview of DSDS+. In this section we define what a discrete-event model is, and how it works. The discussion is presented relative to the DSDS+ simulation tool that we have developed, including it's run-time optimization algorithms that enables DSDS+ to execute substantially faster than comparable discrete-event simulation tools; (4) Summary. In this section, we summarize our findings and 'lessons learned' during the development and application of DSDS+ to model NASA's data systems; (5) Further Information; and (6) Acknowledgements.

Rouff, Christopher↗
NASA NTRS1995

Modeling and characterization of through-the-thickness properties of 3D woven composites

The through-the-thickness properties of three-dimensionally (3D) woven carbon/epoxy composites have been studied. The investigation aimed at the evaluation and development of test methodologies for the property characterization in the thickness direction, and the establishment of fiber architectures were studied: layer-to-layer Angle Interlock, through-the-thickness Orthogonal woven preform with surface pile was also designed and manufactured for the fabrication of tensile test coupons with integrated grips. All the preforms were infiltrated by the resin transfer molding technique. The microstructures of the composites were characterized along the warp and fill (weft) directions to determine the degree of yarn undulations, yarn cross-sectional shapes, and microstructural dimensions. These parameters were correlated to the fiber architecture. Specimens were designed and tested for the direct measurement of the through-the-thickness tensile, compressive and shear properties of the composites. Design optimization was conducted through the analysis of the stress fields within the specimen coupled with experimental verification. The experimentally-derived elastic properties in the thickness direction compared well with analytical predictions obtained from a volume averaging model.

Hartranft, Dru↗
NASA NTRS2002

Science Goal Driven Observing and Spacecraft Autonomy

Spacecraft autonomy will be an integral part of mission operations in the coming decade. While recent missions have made great strides in the ability to autonomously monitor and react to changing health and physical status of spacecraft, little progress has been made in responding quickly to science driven events. For observations of inherently variable targets and targets of opportunity, the ability to recognize early if an observation will meet the science goals of a program, and react accordingly, can have a major positive impact on the overall scientific returns of an observatory and on its operational costs. If the onboard software can reprioritize the schedule to focus on alternate targets, discard uninteresting observations prior to downloading, or download a subset of observations at a reduced resolution, the spacecraft's overall efficiency will be dramatically increased. The science goal monitoring (SGM) system is a proof- of-concept effort to address the above challenge. The SGM will have an interface to help capture higher-level science goals from the scientists and translate them into a flexible observing strategy that SGM can execute and monitor. We are developing an interactive distributed system that will use on-board processing and storage combined with event-driven interfaces with ground-based processing and operations, to enable fast re-prioritization of observing schedules, and to minimize time spent on non-optimized observations. This paper will focus on our strategy for developing SGM and the technical challenges that we have encountered. We will discuss the SGM architecture as it applies to the proposed MIDEX-class mission Kronos. However, the architecture and interfaces will also be designed for easy adaptability to other observing platforms, including ground-based systems and to work with different scheduling and pipeline processing systems.

Jones, Jeremy↗
NASA NTRS2008

An Object-oriented Computer Code for Aircraft Engine Weight Estimation

Reliable engine-weight estimation at the conceptual design stage is critical to the development of new aircraft engines. It helps to identify the best engine concept amongst several candidates. At NASA Glenn (GRC), the Weight Analysis of Turbine Engines (WATE) computer code, originally developed by Boeing Aircraft, has been used to estimate the engine weight of various conceptual engine designs. The code, written in FORTRAN, was originally developed for NASA in 1979. Since then, substantial improvements have been made to the code to improve the weight calculations for most of the engine components. Most recently, to improve the maintainability and extensibility of WATE, the FORTRAN code has been converted into an object-oriented version. The conversion was done within the NASA s NPSS (Numerical Propulsion System Simulation) framework. This enables WATE to interact seamlessly with the thermodynamic cycle model which provides component flow data such as airflows, temperatures, and pressures, etc. that are required for sizing the components and weight calculations. The tighter integration between the NPSS and WATE would greatly enhance system-level analysis and optimization capabilities. It also would facilitate the enhancement of the WATE code for next-generation aircraft and space propulsion systems. In this paper, the architecture of the object-oriented WATE code (or WATE++) is described. Both the FORTRAN and object-oriented versions of the code are employed to compute the dimensions and weight of a 300- passenger aircraft engine (GE90 class). Both versions of the code produce essentially identical results as should be the case. Keywords: NASA, aircraft engine, weight, object-oriented

Tong, Michael T.↗
NASA NTRS2009

An Object-Oriented Computer Code for Aircraft Engine Weight Estimation

Reliable engine-weight estimation at the conceptual design stage is critical to the development of new aircraft engines. It helps to identify the best engine concept amongst several candidates. At NASA Glenn Research Center (GRC), the Weight Analysis of Turbine Engines (WATE) computer code, originally developed by Boeing Aircraft, has been used to estimate the engine weight of various conceptual engine designs. The code, written in FORTRAN, was originally developed for NASA in 1979. Since then, substantial improvements have been made to the code to improve the weight calculations for most of the engine components. Most recently, to improve the maintainability and extensibility of WATE, the FORTRAN code has been converted into an object-oriented version. The conversion was done within the NASA's NPSS (Numerical Propulsion System Simulation) framework. This enables WATE to interact seamlessly with the thermodynamic cycle model which provides component flow data such as airflows, temperatures, and pressures, etc., that are required for sizing the components and weight calculations. The tighter integration between the NPSS and WATE would greatly enhance system-level analysis and optimization capabilities. It also would facilitate the enhancement of the WATE code for next-generation aircraft and space propulsion systems. In this paper, the architecture of the object-oriented WATE code (or WATE++) is described. Both the FORTRAN and object-oriented versions of the code are employed to compute the dimensions and weight of a 300-passenger aircraft engine (GE90 class). Both versions of the code produce essentially identical results as should be the case.

Tong, Michael T.↗
NASA NTRS2018

Runtime Assurance Protection for Advanced Turbofan Engine Control

This paper describes technical progress made in the application of run time assurance (RTA) methods to turbofan engines with advanced propulsion control algorithms that are employed to improve engine performance. It is assumed that the advanced algorithms cannot be fully certified using current verification and validation approaches and therefore need to be continually monitored by an RTA system that ensures safe operation. However, current turbofan engine control systems utilize engine protection logic for safe combustion dynamics and stable airflow through the engine. It was determined that the engine protection logic should continue to be used to provide system safety and should be considered as a part of the overall RTA system. The additional function that an RTA system provides is to perform diagnostics on anomalous conditions to determine if these conditions are being caused by errors in the advanced controller. If this is the case, the RTA system switches operation to a trusted reversionary controller. Initial studies were performed to demonstrate this benefit. The other focus was to improve the performance of the engine protection logic, which was deemed too conservative and reduced engine performance during transient operations. It was determined that the conservative response was due to poor tuning of one of the controller channels within the protection logic. An automatic tuning algorithm was implemented to optimize the protection logic control gains based on minimizing tracking error. Improved tracking responses were observed with no change to the existing protection logic control architecture.

runtime monitoring↗
NASA NTRS2016

Progress on Modular Unmanned Aircraft Technology

Modular unmanned aerial systems (UAS) are a new development in UAS architecture that holds promise for reusable, reconfigurable hosts for science and autonomy payloads. Modularity of airframe subcomponents lowers costs, facilitates rapid field repair, permits holistic optimization, and enables mass-customization of bespoke platforms customizing the aircraft around a given payload or payloads. Without modular UAS, sensors and instruments often must be designed to fit in a non-modifiable airframe. This talk will present how the nexus of modularity, rapid prototyping and design reuse opens up new tradeoffs, and discuss the envisioned benefits, price paid, and enhanced missions made possible by this new approach to aircraft development.

Dahlgren, Robert P.↗
NASA NTRS2023

Channel Measurements for Switching Strategies in Hybrid RF/Optical Communications

Free space optical (FSO) communication links increase data rate, reduce size and power, and increase security. These criteria are particularly important in space communication. Increasing mission complexity and crowding of lower frequency bands is driving the need for optical communications. This makes FSO communication technology extremely attractive, and there is significant ongoing work towards the development of FSO transceivers, ground stations, and relays. Notable projects include the Laser Communications Relay Demonstrator (LCRD), Integrated LCRD Low-Earth Orbit User Modem and Amplifier Terminal (ILLUMA-T), and CubeSat Laser Infrared Crosslink (CLICK) CubeSats. These technologies will eventually operate in unison with existing Radio Frequency (RF) systems, but there is little experimental investigation of such hybrid networks. This paper presents some experimental underpinnings of switching strategies for hybrid RF/FSO systems in various attenuation conditions. A 170 m optical path was constructed in an enclosed test chamber where atmospheric conditions can be tightly controlled. The performance of a 1550 nm infrared FSO link was evaluated in this chamber under varying conditions of turbulence and jitter. The system will eventually be used to investigate switching criteria between the FSO and RF channels. Optimizing the use of RF/FSO communication links will allow data rate, size, power, and security improvements. Therefore, this research will help to mature the network architecture and improve the performance of communication networks to be used for LEO, GEO, Lagrange, Lunar missions and beyond.

Space Networks↗
DOE OSTI2025

3D printing of architected sulfur cathodes with dual-site atomic catalysts for accelerated polysulfide kinetics and Li-ion transport in high areal-loading lithium–sulfur batteries

The practical deployment of lithium–sulfur batteries (LSBs) is hindered by fundamental limitations in conventional slurry-cast cathodes, including poor sulfur utilization, sluggish ion transport, and low areal capacity, particularly in thick electrodes required for high energy density. To address these challenges, we present direct ink writing (DIW) as an additive manufacturing strategy to fabricate advanced current-collector-free, 3D-printed sulfur cathodes (3DP S@CoNi-DSACs/NC) with hierarchically porous architectures that enhance lithium-ion diffusion, promote electrolyte penetration, and reduce interfacial resistance. The synergistic effects of Co/Ni dual-atom sites accelerate redox kinetics and mitigate polysulfide shuttling. As a result, the optimized 3DP cathode with a sulfur loading of 5.4 mg cm −2 demonstrated excellent rate capability, delivering a high reversible capacity of 1041.4 mAh g −1 at 1C with 85.5% capacity retention after 1000 cycles, significantly outperforming its cast counterpart. Remarkably, even at a higher sulfur loading of 8.1 mg cm −2 , the 3DP cathode maintains outstanding performance, achieving a discharge capacity of 1538.4 mAh g −1 and an areal capacity of 12.5 mAh cm −2 at 0.1C. This study not only demonstrates the functional integration of catalytically active materials into 3D printable sulfur cathode architectures but also offers a scalable and transformative platform for building high-performance LSBs beyond conventional electrode manufacturing methods.

3D electrode↗