Single-step laser-printed integrated sulfur cathode toward high-performance lithium–sulfur batteries

Rongliang Yang, Yi Chen, Yexin Pan, Minseong Kim, Huan Liu, Connie Kong Wai Lee, Yangyi Huang, Aidong Tang, Feiyue Tu, Tianbao Li and Mitch Guijun Li ()
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Rongliang Yang: Clear Water Bay
Yi Chen: Clear Water Bay
Yexin Pan: Clear Water Bay
Minseong Kim: Clear Water Bay
Huan Liu: Clear Water Bay
Connie Kong Wai Lee: Clear Water Bay
Yangyi Huang: Clear Water Bay
Aidong Tang: Central South University
Feiyue Tu: Changsha Research Institute of Mining and Metallurgy Co. LTD
Tianbao Li: Changsha Research Institute of Mining and Metallurgy Co. LTD
Mitch Guijun Li: Clear Water Bay

Nature Communications, 2025, vol. 16, issue 1, 1-12

Abstract: Abstract Lithium–sulfur batteries are expected to supersede existing lithium-ion batteries due to the high theoretical energy density of sulfur cathodes (positive electrodes). Unfortunately, inefficient redox reactions and the “shuttle effect” hinder their commercial development. Assembling high-performance nanostructured sulfur host materials into a sulfur cathode presents a viable solution. However, fabricating host materials and preparing sulfur cathodes involve complicated, multistep, and labor-intensive processes under varying temperatures and conditions, raising concerns about efficiency and cost in practical production. Herein, we propose a single-step laser printing strategy to prepare high-performance integrated sulfur cathodes. During the high-throughput laser-pulse irradiation process, the precursor donor is activated, producing jetting particles that include in-situ synthesized halloysite-based hybrid nanotubes, sulfur, and glucose-derived porous carbon. After laser printing, a composite layer, containing host materials, active materials, and conductive components, is uniformly coated onto a carbon fabric acceptor, forming an integrated sulfur cathode. The laser-printed sulfur cathodes exhibit high reversible capacity and low capacity attenuation during cycling measurements. Furthermore, the laser-printed high-loading samples show high performance in both coin and pouch lithium–sulfur cells. This strategy would simplify the fabrication process in lithium–sulfur battery industry and inspire advancements in other battery research.

Date: 2025
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DOI: 10.1038/s41467-025-57755-0

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