Sometimes, scientific breakthroughs don’t require a trip across the globe, just a walk down the hallway. That was the case at Binghamton University, where a long-standing project to develop bacteria-powered batteries received a major upgrade when two professors from different departments decided to combine their expertise. The result? One of the most efficient bacteria-based biobatteries ever developed, made without lithium, toxic chemicals, or expensive imports.
Professor Seokheun “Sean” Choi, an expert in bioelectronics at Binghamton’s Thomas J. Watson College of Engineering and Applied Science, has been researching microbial fuel cells for over a decade. His work focused on bacteria-powered batteries, using microbes to generate electricity through natural metabolic processes. But despite years of effort, a key limitation remained: the battery’s material structure, especially the anode.
Traditional stainless-steel mesh made a durable and conductive platform for bacterial growth but lacked the surface precision needed for optimal energy generation. “A two-dimensional anode is not efficient,” Choi explained. “Nutrients will not be delivered effectively to the bacteria, and their waste cannot go out effectively.”
To tackle this, Choi partnered with Assistant Professor Dehao Liu from the Department of Mechanical Engineering, who specializes in laser powder bed fusion (LPBF, a high-precision 3D printing technique that builds metal structures layer by layer. According to Liu, “LPBF is ideal for biobatteries because it enables high-precision, customizable 3D structures with complex geometries, essential for maximizing surface area and energy density.”
Using LPBF, the team designed and printed customized anodes, cathodes, and sealing covers, assembling them like high-tech Lego blocks. This approach provided nanoscale control over the battery’s design, solving the long-standing problem of inefficient nutrient exchange in traditional setups.
The outcome was remarkable. A stack of six biobatteries was able to generate nearly 1 milliwatt of power enough to run a 3.2-inch LCD screen. The stainless-steel components weren’t just efficient; they were reusable, too. “You can detach the bacterial cells and then reuse them, and we showed after a number of uses that power levels are maintained,” Choi said.
This research also builds on the PhD work of Assistant Professor Anwar Elhadad, who once studied under Choi. His dissertation focused on sustainable energy-harvesting systems, and the current project helped overcome key issues he faced, particularly in scaling microbial fuel cells. Elhadad called the collaboration “inspiring and intellectually stimulating,” praising Choi’s leadership for encouraging fresh thinking and innovation.
Looking ahead, the team aims to further streamline production by integrating the printing of all components into a single process. They’re also working on a power management system, similar to those used in solar energy setups, to regulate battery performance.
The research was published in the journal Advanced Energy & Sustainability Research.