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Abstract This paper details the design and operation of a testbed to evaluate the concept of autonomous manufacturing to achieve a desired manufactured part performance specification. This testbed, the autonomous manufacturing system for phononic crystals (AMSPnC), is composed of additive manufacturing, material transport, ultrasonic testing, and cognition subsystems. Critically, the AMSPnC exhibits common manufacturing deficiencies such as process operating window limits, process uncertainty, and probabilistic failure. A case study illustrates the AMSPnC function using a standard supervised learning model trained by printing and testing an array of 48 unique designs that span the allowable design space. Using this model, three separate performance specifications are defined and an optimization algorithm is applied to autonomously select three corresponding design sets to achieve the specified performance. Validation manufacturing and testing confirms that two of the three optimal designs, as defined by an objective function, achieve the desired performance, with the third being outside the design window in which a distinct bandpass is achieved in phononic crystals (PnCs). Furthermore, across all samples, there is a marked difference between the observed bandpass characteristics and predictions from finite elements method computation, highlighting the importance of autonomous manufacturing for complex manufacturing objectives. 

Abstract Solid‐state lithium metal batteries with garnet‐type electrolyte provide several advantages over conventional lithium‐ion batteries, especially for safety and energy density. However, a few grand challenges such as the propagation of Li dendrites, poor interfacial contact between the solid electrolyte and the electrodes, and formation of lithium carbonate during ambient exposure over the solid‐state electrolyte prevent the viability of such batteries. Herein, an ultrathin sub‐nanometer porous carbon nanomembrane (CNM) is employed on the surface of solid‐state electrolyte (SSE) that increases the adhesion of SSE with electrodes, prevents lithium carbonate formation over the surface, regulates the flow of Li‐ions, and blocks any electronic leakage. The sub‐nanometer scale pores in CNM allow rapid permeation of Li‐ions across the electrode–electrolyte interface without the presence of any liquid medium. Additionally, CNM suppresses the propagation of Li dendrites by over sevenfold up to a current density of 0.7 mA cm⁻²and enables the cycling of all‐solid‐state batteries at low stack pressure of 2 MPa using LiFePO₄cathode and Li metal anode. The CNM provides chemical stability to the solid electrolyte for over 4 weeks of ambient exposure with less than a 4% increase in surface impurities. 

Abstract Suppressing Li dendrite growth has gained research interest due to the high theoretical capacity of Li metal anodes. Traditional Celgard membranes which are currently used in Li metal batteries fall short in achieving uniform Li flux at the electrode/electrolyte interface due to their inherent irregular pore sizes. Here, the use of an ultrathin (≈1.2 nm) carbon nanomembrane (CNM) which contains sub‐nanometer sized pores as an interlayer to regulate the mass transport of Li‐ions is demonstrated. Symmetrical cell analysis reveals that the cell with CNM interlayer cycles over 2x longer than the control experiment without the formation of Li dendrites. Further investigation on the Li plating morphology on Cu foil reveals highly dense deposits of Li metal using a standard carbonate electrolyte. A smoothed‐particle hydrodynamics simulation of the mass transport at the anode–electrolyte interface elucidates the effect of the CNM in promoting the formation of highly dense Li deposits and inhibiting the formation of dendrites. A lithium metal battery fabricated using the LiFePO₄cathode exhibits a stable, flat voltage profile with low polarization for over 300 cycles indicating the effect of regulated mass transport.