Abstract
Silicon is a promising anode material for next-generation lithium-ion batteries (LIBs) due to its high theoretical capacity. However, its practical use is hindered by significant volume expansion during charge cycles, which causes poor cycling stability. Intense pulsed light technology offers a solution through rapid, selective heating, enabling nanoscale transformations without damaging substrates. Here, a scalable approach for creating silicon patterns on polymer foils and converting them into nanoscale composite layers under ambient conditions is presented. The use of inkjet printing in conjunction with intense Pulsed Light treatment is demonstrated to generate localized temperatures in excess of 1,940 °C within milliseconds, whilst maintaining the integrity of the polymer substrate. This rapid heating method induces local carbonization of the polymer, thereby converting the Si nanoparticles into a new silicon carbide (SiC) embedded in a few-layer graphene composite electrode. The resulting heterostructure anode exhibits excellent electrochemical performance, improved cycling stability, and enhanced rate capability, positioning it as a promising binder-free silicon anode for next-generation lithium-ion batteries.