Aluminum–air (Al–air) batteries are considered one of the most promising next-generation energy storage devices. In this paper, we carry out an orthogonal experimental study on the SLM printing process parameters in 3D-printed Al–air battery anodes. The surface roughness, densification, and discharge performance of the electrodes under different process parameters are observed to reveal the effects of different process parameters on the forming quality and discharge performance of aluminum–air battery anodes. The results show that the laser power is the most important factor affecting the surface roughness of the porous aluminum anode, and the scanning spacing is the most important factor affecting the densification. The best printing parameters for the porous aluminum anode can be obtained when the laser power is 325 W, the scanning speed is 1000 mm/s, the scanning spacing is 0.12 mm, and the thickness of the powder spread is 0.03 mm. At this time, the surface roughness of the porous aluminum anode obtained by this process parameter is 15.01 μm, the densification is 94.97%, and the discharge is stable with a high value. In addition, we also carry out data validation to ensure that the data we obtain are optimal and valid.

Influence of Laser Process Parameters on the Forming Quality and Discharge Performance of 3D-Printed Porous Anodes for Al–Air Batteries