This paper describes a totally solid-state, rechargeable, long cycle life lithium-oxygen battery cell. The cell is comprised of a Li metal anode, a highly Li-ion conductive solid electrolyte membrane laminate fabricated from glass-ceramic ͑GC͒ and polymerceramic materials, and a solid-state composite air cathode prepared from high surface area carbon and ionically conducting GC powder. The cell exhibited excellent thermal stability and rechargeability in the 30-105°C temperature range. It was subjected to 40 charge-discharge cycles at current densities ranging from 0.05 to 0.25 mA/cm 2 . The reversible charge/discharge voltage profiles of the Li-O 2 cell with low polarizations between the discharge and charge are remarkable for a displacement-type electrochemical cell reaction involving the reduction of oxygen to form lithium peroxide. The results represent a major contribution in the quest of an ultrahigh energy density electrochemical power source. We believe that the Li-O 2 cell, when fully developed, could exceed specific energies of 1000 Wh/kg in practical configurations.

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The composite of nitrogen-doped carbon (N-C) blend with lithium aluminum germanium phosphate (LAGP) was studied as cathode material in a solid-state lithium-oxygen cell. Composite electrodes exhibit high electrochemical activity toward oxygen reduction. Compared to the cell capacity of N-C blend cathode, N-C/LAGP composite cathode exhibits six times higher discharge cell capacity. A significant enhancement in cell capacity is attributed to higher electrocatalytic activity and fast lithium ion conduction ability of LAGP in the cathode.

A novel rapid prototyping technology incorporating a curved layer building style was developed. The new process, based on laminated object manufacturing (LOM), was designed for efficient fabrication of curved layer structures made from ceramics and fiber reinforced composites. A new LOM machine was created, referred to as curved layer LOM. This new machine uses ceramic tapes and fiber prepregs as feedstocks and fabricates curved structures on a curved‐layer by curved‐layer basis. The output of the process is a three‐dimensional “green” ceramic that is capable of being processed to a seamless, fully dense ceramic using traditional techniques. A detailed description is made of the necessary software and hardware for this new process. Also reviewed is the development of ceramic preforms and accompanying process technology for net shape ceramic fabrication. Monolithic ceramic (SiC) and ceramic matrix composite (SiC/SiC) articles were fabricated using both the flat layer and curved layer LOM processes. For making curved layer objects, the curved process afforded the advantages of eliminated stair step effect, increased build speed, reduced waste, reduced need for decubing, and maintenance of continuous fibers in the direction of curvature.

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