We have developed transformational, and intrinsically safe, all-solid-state Li-ion batteries (SSLiBs), by incorporating high conductivity garnet-type solid Li-ion electrolytes into tailored tri-layer microstructures, by low-cost solid oxide fuel cell (SOFC) fabrication techniques to form electrode supported dense thin-film (~10μm) solid-state electrolytes. The microstrucurally tailored porous garnet scaffold support increases electrode/electrolyte interfacial area, overcoming the high impedance typical of planar geometry SSLiBs resulting in an area specific resistance (ASR) of only ~2 to 7 Ωcm^-2 at room temperature. The unique garnet scaffold/electrolyte/scaffold structure further allows for charge/discharge of the Li-metal anode and cathode scaffolds by pore-filling, thus providing high depth of discharge ability without mechanical cycling fatigue seen with typical electrodes. Moreover, these scalable multilayer ceramic fabrication techniques, without need for dry rooms or vacuum equipment, provide for dramatically reduced manufacturing cost.

Fabrication of supported dense thin-film garnet electrolytes, their ability to cycle Li-metal at high current densities with no dendrite formation, and results for Li-metal anode/garnet-electrolyte based batteries with a number of different cathode chemistries will be presented.