Traditional batteries are rigid cylinders or rectangular blocks that limit the design of electronic devices. In our R&D lab, we break these limitations by developing a screen-printed manganese–zinc battery. This is a power source that can be printed in virtually any shape – from flat panels to complex three-dimensional forms. Thanks to screen-printing technologies, we can create batteries only a few millimeters thick that integrate perfectly with keyboards and control interfaces.

Video:
https://www.youtube.com/watch?v=lwPdTREpF20

What exactly is a printed battery?

A printed battery is an electrochemical cell manufactured using printing techniques. Instead of assembling ready-made components inside a traditional housing, all battery elements are created as successive layers precisely deposited onto a substrate. Our lab uses specialized conductive inks and electrode pastes for this purpose. Each layer has strictly defined chemical and electrical properties that must work together to generate a stable voltage source. The process resembles multilayer printing, but requires much greater precision and control over material properties.

Printed batteries have enormous potential and will find applications in wearable electronics, IoT sensors, smart labels, and medical devices in the future. Medical applications are particularly promising – transdermal patches with built-in sensors, temporary implants, or vital-sign monitoring systems. The flexibility and biocompatibility of materials open up new possibilities for medical device design.

How do we create our batteries?

The process begins with preparing specialized compositions – electrode pastes, conductive inks, and electrolytes with strictly controlled viscosity. Each material must fulfill a dual role: behave like typical printing ink during deposition, and then transform into an active electrochemical component.

The next step is printing the zinc anode onto a flexible substrate. Then we apply a separator layer, which prevents direct contact between the electrodes while allowing ion flow. The next layer is the electrolyte, and finally we print the manganese cathode.

Each layer must dry thoroughly and chemically stabilize before the next one is applied. We control thickness, coating uniformity, and electrical properties at every production stage. Finally, we test the output voltage, capacity, and battery stability under various operating conditions.

The most challenging aspect is synchronizing the properties of all layers. The anode must release electrons, the cathode must accept them, and the electrolyte must enable ion transport – all within a structure only a few millimeters thick. This goes far beyond standard printing and requires a deep understanding of both printing technologies and electrochemistry.

The result is a power source that can be shaped freely already at the production stage. We no longer have to adapt the device design to rigid battery dimensions – instead, we adapt the battery to the design requirements.

How is a printed battery structured?

Our screen-printed manganese–zinc battery consists of several precisely deposited layers. The cathode is made of manganese dioxide, the anode of zinc powder, and the electrolyte is a special ion-conducting paste. Each component is printed as a separate layer, forming a complete electrochemical cell.

Manganese dioxide in the cathode accepts electrons during discharge, while zinc in the anode releases them. The electrolyte enables ion transport between the electrodes, closing the electrical circuit. This process generates a voltage of about 1.5 volts – similar to traditional alkaline batteries.

The total thickness of the battery is only a few millimeters, and its shape can be freely adapted to the device requirements. This design flexibility is the greatest advantage of printed battery technology.

What are the advantages of printed power sources?

Printed batteries offer possibilities unavailable to traditional cells. First of all, they can be given virtually any shape – from rectangular panels to complex forms tailored to a specific device. Our Christmas tree ornament with a built-in battery is an example of how the technology can blend into the aesthetic design of a product. This, however, is only the tip of the iceberg when it comes to the potential of printed power sources.

Integration with electronics
Printing technology allows direct integration of the battery with electronic circuits. Instead of connecting a separately manufactured battery to a PCB, we can print the power source directly onto the same surface as conductive traces and components. In industrial keyboards, this means the possibility of creating a fully autonomous interface – without external power supplies or complex wiring.

Customization of electrical parameters
Another key advantage is the ability to precisely tailor electrical characteristics. By modifying the composition of electrode pastes, layer thickness, or electrode geometry, we can influence output voltage, capacity, and discharge curves. This allows us to create batteries perfectly matched to the requirements of a specific device – from low voltage for delicate sensors to high capacity for long-term operation.

Production economics
Printing technology also offers economic benefits, especially in medium and large production volumes. The manufacturing process is much faster than traditional cell assembly, and the ability to print multiple batteries simultaneously on a single sheet drastically reduces unit costs. Additionally, we eliminate the need for expensive metal or plastic housings, which translates into material savings.

Mechanical flexibility
Printed batteries can be manufactured on flexible substrates, opening up applications in devices that bend or deform during operation. This is particularly important in modern touch interfaces and wearable devices, where a rigid battery could limit functionality or user comfort.

Limitations and technological challenges

Printed batteries also have their limitations. Their capacity is usually lower than that of traditional cells of similar size. Mechanical durability is another challenge, especially when flexible substrates are used. Repeated bending can damage the electrode structure and reduce battery performance. That is why we continue to research and develop specialized material compositions that maintain flexibility without sacrificing electrical properties.

Qwerty printed battery – building technological advantage

The foundation of the quality and reliability of our keyboards is the knowledge we gain in practice by testing, validating, and developing technologies available on the market. We know that what today is presented as an innovative gadget or technological curiosity may tomorrow become the foundation of consumer and industrial electronics. That is why we do not wait for printed power sources to mature on their own – we actively develop and improve them in our lab. This approach not only allows us to stay ahead of the competition and maintain a leading position in the industry, but above all to offer our clients solutions truly tailored to their needs.