Solid-State Batteries (SSBs) offer a paradigm shift in energy storage, promising enhanced safety, higher energy density, and compatibility with lithium metal anodes, thereby addressing critical limitations of conventional lithium-ion batteries. Prominent solid electrolytes, including NaSICON-type ceramics, polyethylene oxide (PEO) polymers, and their composites, demonstrate high ionic conductivity and mechanical stability; however, their scalable and efficient fabrication remains a significant hurdle. Additive Manufacturing (AM) techniques are emerging as a pathway for producing complex battery components; however, the role of Binder Jetting AM (BJAM) in fabricating functional solid electrolytes is notably underexplored. This work investigates the current state of solid electrolytes and critically evaluates various AM techniques for SSB fabrication, with a focus on BJAM. The review identifies key challenges, including powder packing density, controlling binder-powder interactions, and structural integrity during post-processing in BJAM. Addressing these limitations, a novel vacuum-assisted powder transfer system (VAPTS) is proposed to implement in BJAM, using a NaSICON-PEO composite and two distinct water-based binders, while aiming to enhance green part integrity and reduce post-sintering porosity. Analysis of existing literature reveals that while BJAM offers industrial compatibility and geometric versatility for ceramic component fabrication, electrochemical performance is limited by inadequate powder packing density and unoptimized binder-material compatibility. This comprehensive review identifies critical pathways for leveraging BJAM to overcome current manufacturing limitations in SSBs, highlighting a significant gap in the electrochemical assessment of BJAM-processed electrolytes. The proposed VAPTS with optimized binder and composite formulations, is crucial for developing scalable, cost-effective, and pressure-independent fabrication processes for advanced solid electrolytes.
