Founded in 2016 by CEO Robert Bagheri, Sakuu has evolved from developing battery material kits to producing 3D printed batteries in various shapes and sizes. At the heart of these efforts is the Kavian platform—a manufacturing platform for dry electrode printing. This platform employs additive manufacturing (AM) technology to build battery layers sequentially, enabling designs that go beyond traditional formats. The platform is set to commercialize in 2025 and has gained industry recognition for its innovative approach.
Focusing on Customer Needs: Dry Electrode Printing
Sakuu specializes in printing dry materials, and its Kavian platform has applied 3D printing technology to large-scale battery production. The company has developed a process where the battery's current collector foil moves beneath the deposition head instead of moving the deposition head itself. Arwed Niestroj, President and Chief Operating Officer of Sakuu, explained: "This allows us to increase the speed of material deposition. More importantly, we need to apply the correct process to each layer, controlling thickness, speed, and quality. Coordinating the process, materials, and final layers is the core capability for scaling up."
Niestroj noted that while the initial focus was on 3D printing entire batteries, the company adjusted its approach based on customer feedback: "Interestingly, our customers indicated that printing complete batteries was not their top priority. Instead, they wanted to start with components, specifically dry electrode printing." As a result, the first commercial version of the Kavian platform focuses on producing dry electrodes (including cathodes and anodes) with various chemical compositions. The system uses a roll-to-roll printing method, offering throughput and handling characteristics comparable to traditional wet coating production lines, along with additional operational and environmental advantages.
Kavian Platform: Dry Electrode Printing vs. Traditional Wet Processes
A major advantage of the Kavian platform is its lower capital expenditure. Unlike traditional wet coating production lines that rely on large, high-energy-consuming furnaces and off-site solvent recovery systems, the dry process reduces operational costs and simplifies factory layout. Additionally, it allows for the reuse of excess materials—a significant benefit, as raw material costs can account for over 80% of battery production costs.
Sakuu highlights a key challenge of traditional wet processes: the evaporation of solvents is difficult to control at the particle level, often leading to electrode defects such as unevenness and reduced yield. In contrast, the dry process eliminates solvent evaporation. Once the process parameters are set according to the customer's layer specifications, the equipment is fine-tuned to meet electrode quality and output requirements. This approach is seen as a way to reduce defect rates and improve yield.
An independent consulting firm has confirmed that the platform can also reduce the carbon footprint by approximately 55% while avoiding water usage. For the entire battery cell manufacturing process from "cradle to gate," based on typical U.S. energy mix, the carbon footprint is reduced by about 40%. However, these benefits depend on careful process optimization and material handling. Future developments aim to further improve efficiency, including structured electrodes for new functionalities, alternative battery designs, and strategies to reduce end-of-life battery recycling costs.
Operational Compliance and Scalability
Kavian complies with standard equipment certifications in various operational regions, including safety and power compatibility requirements. Niestroj explained: "The overall process is independent of specific battery applications. The batteries produced can be certified according to conventional protocols for electric vehicles, grid energy storage, drones, defense, and consumer electronics."
Although electrode processing remains highly demanding, there are few scalable practical solutions. Sakuu is currently collaborating with SK On for pre-commercial testing to evaluate requirements for producing final electrodes and mass production equipment. These pilot studies aim to validate the manufacturing technology, identify limitations, and provide references for potential applications.
Supporting Regional Supply Chain Flexibility
Against a backdrop of rapidly changing geopolitical dynamics, interest in regionalizing battery supply chains is growing to reduce reliance on a few dominant suppliers and overseas manufacturing hubs. Recent events, such as trade tensions and logistical challenges from the pandemic, have highlighted the vulnerabilities of global supply networks.
Niestroj explained that the Kavian platform is designed to support localized production of key components and offers chemistry-agnostic functionality, allowing the use of various electrode materials—including NCM, LFP, NCA, graphite, silicon-graphite, and other dry particles suitable for battery-grade layers, as well as solid-state chemistries.
"Customers can decide where to source their materials—they are not locked into specific suppliers or foreign sources. For example, Western countries have supply options in South Korea, Germany, the U.S., and elsewhere. We pre-treat the materials chosen by customers to ensure printability and then print them on our equipment," Niestroj added.
Beyond Batteries: Expanding Energy Storage Applications
The Kavian platform is being adapted for broader energy storage solutions, including high-power capacitors. Potential use cases extend to AI data centers, where stable, high-performance energy storage is critical for managing power fluctuations. Niestroj said: "Lithium-ion capacitors are essential for handling sudden surges in demand. This is where our technology excels—combining high power and high energy."
To meet these needs, Kavian is designed for high throughput, with speeds comparable to specialized laser printers—approximately 100 square meters per minute. Achieving this requires precise calibration of equipment and materials. Niestroj emphasized that collaboration with industry partners will be key to integrating such technologies. Early production facility installations are expected to support rapid scaling for plants with large annual capacities.
Looking ahead, the dry printing process could also enable new battery architectures, from alternative methods of sealing active materials to replacing traditional aluminum and copper current collectors with lighter or lower-cost solutions. Niestroj added: "With our extensive experience in the semiconductor industry, we understand the transformative power of adopting new technologies... The key to continued success lies in continuous innovation."
Expanding the 3D Printed Battery Ecosystem
The rapid growth of the 3D printed battery industry further solidifies Sakuu's market position. According to Market Research Intellect, the global 3D printed battery market is projected to grow from $11.86 billion in 2025 to $21.89 billion in 2033, with a compound annual growth rate (CAGR) of 10.75%. Meanwhile, the International Energy Agency's (IEA) "Global EV Outlook 2025" predicts that global electric vehicle battery demand will surge from about 1 terawatt-hour (TWh) in 2024 to over 3 TWh by 2030.
As battery demand continues to rise, manufacturers are increasingly adopting additive manufacturing methods to scale production, improve efficiency, and reduce costs. Alongside Sakuu, Addionics is also advancing the field of 3D printed batteries with its smart 3D electrode technology, driving innovation through structural improvements. Instead of altering battery chemistry, Addionics focuses on redesigning the structure of battery current collectors to reduce internal resistance, enhance mechanical stability, and improve thermal management. These solutions can be integrated into existing production lines without major retrofitting, resulting in safer, higher-performing, and more efficient batteries.
Academic research is also contributing to innovations in 3D printed batteries. In 2023, the University of Texas at El Paso (UTEP) joined a $2.5 million program led by NASA to 3D print rechargeable batteries using lunar and Martian regolith. UTEP received $615,000 in funding to collaborate with Youngstown State University and Formlabs on developing deformable batteries for space missions, utilizing local materials to reduce payload weight. The research team employed additive manufacturing techniques such as material extrusion (ME) and vat photopolymerization (VPP) to successfully produce battery components, including electrodes, electrolytes, and current collectors.
