Enhanced Energy Storage Devices and Efficiency Using Advanced Micro-Nano Manufacturing Processes: A Mechanical Engineering Perspective on Thermo-Mechanical Integrity and Reliability

The durability and efficiency of electrochemical energy storage devices, including lithium-ion batteries and supercapacitors, are fundamentally constrained by mechanical and thermo-mechanical degradation. During electrochemical cycling, repeated volumetric expansion and contraction of solid-state electrodes generate internal stresses that can lead to particle fracture, electrode delamination, and loss of structural integrity. These damage mechanisms increase internal resistance, reduce capacity, and shorten device lifespan, while coupled thermal effects further accelerate degradation through a self-reinforcing feedback process. Conventional slurry-based electrode manufacturing offers limited control over the microstructural architecture, leading to electrodes that are prone to stress concentration and thermal instability. This review examines the role of advanced micro- and nano-manufacturing techniques, including electrospinning, freeze casting, atomic layer deposition, laser processing, and direct ink writing, in enabling mechanically robust and thermally resilient electrode architectures. From an engineering design perspective, these approaches allow the fabrication of compliant, hierarchical structures that accommodate strain, mitigate stress accumulation, and enhance heat dissipation. The review examines the interplay between fabrication methods, microstructure, mechanical behavior, and electrochemical performance, with a particular focus on fatigue, crack initiation, and growth. Finally, key research gaps are identified, including the lack of standardized mechanical testing, limited long-term fatigue data, and challenges in scalable manufacturing. The integration of multi-physics modeling and digital twin frameworks is proposed as a pathway toward more reliable next-generation energy storage systems.