For the first time, scientists have fabricated multi-layer, reconfigurable batteries that can bend, adapt and tune their own voltage – offering a potential power source for future wearable devices, sensors and soft robotics.
A research team led by Professor Lin Gui at the Institute of Physics and Chemistry, Chinese Academy of Sciences, fabricated the multi-layer flexible batteries using a combination of liquid metal microfluidic perfusion and plasma-based reversible bonding techniques.
Traditional batteries are rigid and difficult to integrate into systems designed to bend, stretch, or twist. The new method addresses these limitations by creating electrodes and connections that are not only flexible but also reconfigurable on demand.
‘Unlike regular batteries, which are rigid and fixed in performance, our batteries allow the voltage to be regulated internally by adjusting microchannel structures. We don’t need any additional external circuitry and increased design flexibility,’ said Professor Gui.
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At the core of the technology is the controlled infusion of a specially formulated gallium–tin–zinc alloy (Ga52.5Sn39.5Zn8) into microfluidic channels. This alloy provides both deformability and stability in alkaline environments, overcoming long-standing challenges in the use of liquid metals for energy storage. Multi-layer channel architectures further enable the stacking and reconfiguration of cells, while 3D printing allows precise adjustment of cell numbers and interconnections.
‘Our approach combines liquid metal perfusion with reversible bonding techniques we developed earlier, so we can package the electrodes securely while maintaining full flexibility,’ said Professor Gui. ‘Using a non-eutectic alloy gives both mechanical deformability and chemical stability in alkaline environments, which has been a big challenge in earlier liquid-metal battery designs.’
Potential applications are wide ranging: from long-lasting, flexible power for wearable health monitors and soft sensors to biocompatible electronics and advanced soft robots. The researchers are now focused on improving corrosion resistance, refining microfluidic designs for more precise control, and miniaturising the technology for integration into next-generation electronics.
The research has been published in International Journal of Extreme Manufacturing.