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Abstract

This is a comprehensive review of nanomaterial strategies for developing solid-state batteries in the future beyond lithium-ion technology. It discusses key challenges such as ionic conductivity, interfacial stability, and scalable manufacturing. Nanomaterials provide the ultimate means to control electrochemical processes at atomic scales, enabling solid-state systems with energy densities above 500 Wh/kg, enhanced safety from non-flammable electrolytes, and longer cycle life.

The review offers an in-depth analysis of advanced manufacturing methods, including suspension plasma spray (SPS), atomic layer deposition (ALD), and nano-level 3D printing for fabricating nanostructured components. Sulfide solid-state electrolytes demonstrate remarkable ionic conductivities of up to 10-2 S/cm, while garnet-type ceramics achieve excellent interfacial contact through controlled phase distribution. Ionic conductivities and thermal stability in polymer-based electrolytes are significantly improved with innovative 2D nanomaterials, especially boron nitride nanosheets. Three-dimensional nanostructured architectures reduce impedance and enhance charge transfer kinetics compared to ALD-based interface engineering, which limits dendrite growth.

Despite substantial progress, several critical obstacles remain in transitioning from laboratory devices to large-scale manufacturing. Manufacturing complexity and economic barriers hinder increased production. Pricing is currently much higher than that of conventional lithium-ion systems, with price parity expected in the early to mid-2030s. Nonetheless, hybrid manufacturing approaches that combine the precision of ALD with the scalability of 3D printing could offer new opportunities.

Future advances depend on collaborations between industry and academia, as well as sustainable materials design for use in electric vehicles and grid storage. This review outlines the pathway to commercial deployment, connecting fundamental research with practical manufacturing considerations essential for achieving global energy transition targets.

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