4D printing meets electrochemistry: Programmable dampers for vibration-resilient lithium-ion batteries

Random vibration in electrical vehicles (EVs) can accelerate degradation in lithium-ion batteries. This study investigates a programmable vibration-isolation concept based on quasi-zero-stiffness (QZS) cylindrical dampers manufactured by rotary 4D printing. Two inversely designed damper architectures were evaluated in two thermomechanical states, programmed and recovered states. Each configuration was first characterised using swept-sine transmissibility to identify resonance and isolation regions and then tested under an IEC 62660–2 random vibration profile for 24 h with the frequency range of 10–2000 Hz and the acceleration of 3 g, applied along a single radial axis. Cell performance was quantified before and after vibration using CC-CV cycling, electrochemical impedance spectroscopy (EIS), and average discharge voltage (DVavg). The sine-sweep response showed a dominant resonance near 18–20 Hz and transmissibility below unity above approximately 30–40 Hz. Under random excitation, both programmed dampers reduced transmitted vibration broadly above 40 Hz, including the broadband attenuation, extending to 1000–2000 Hz. Electrochemical results showed the role of 4D printing programming in battery capacity retention, impedance growth, and DVavg stability, indicating that rotary 4D-printed QZS dampers can reduce transmitted vibration and moderate vibration-linked performance drift in EV batteries given further improvement in mechanical durability to avoid band-limited amplifications. • Developing a novel processing approach of shape memory materials for programmed vibration attenuation of batteries. • Inversely design and rotary 3D printing of programmable vibration isolation cylindrical architectures. • Presenting a programmable 4D-printed framework for vibration-resilient energy storage • Integrated mechanical–electrochemical validation of 4D-printed damper on lithium-ion cell performance.