Tunable electrical and mechanical properties of anode foils for aluminum electrolytic capacitors prepared by additive manufacturing technology

An additive manufacturing technology was used to produce anode foils with different polystyrene microsphere (PSM). The effect of PSM addition in the range of 0–20 vol% on the specific capacitance and bending strength of the anode foils was investigated. Scanning electron microscopy analysis confirms the presence of pores in the anode foils, which is attributed to the addition of PSM. The porosity and pore diameter of the anode foils increase with increasing PSM content, resulting in an initial increase and then a decrease in specific capacitance, as well as a gradual increase in bending strength. At a PSM addition of 12.5 vol%, the anode foils exhibit a high specific capacitance of 0.927 μF/cm2 and a bending strength of over 120 times greater, meeting the specific capacitance and bending strength requirements for anode foils in aluminum electrolytic capacitors. These findings suggest that incorporating PSM into anode foils is an effective method for adjusting their specific capacitance and bending strength.