Systems and methods for laser additive manufacturing for structured battery components

A method for creating a powder for use in a selective laser sintering additive manufacturing (AM) application to form a battery cathode, the method comprising:

• providing a cathode active material, a carbon material and a binder material;
• mixing the cathode active material and the binder material together in a first ratio in a roller mixer for a first time period at a first rotational speed, to produce a first mixture of active material and binder material, the first ratio including a ratio of from 70:20 to 90:2 of the cathode active material and the binder material;
• adding the carbon material to the first mixture of cathode active material and binder material in a second ratio in the roller mixer, the second ratio including a ratio of 10:90 to 2:98 of the carbon material and the first mixture of cathode active material and binder material;
• and
• mixing the carbon material with the first mixture of cathode active material and binder material in the roller mixer at a second predetermined speed for a second time period to form a homogeneous powder mixture.