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- Aluminum-ion Structural Battery Proof of ConceptPublication . Silva, Gonçalo Filipe Trindade da; Pereira, João Pedro Nunes; Silva, Abílio Manuel Pereira da; Dutra, Thiago AssisThis thesis focuses on the successful development of an aluminum-ion structural battery, which addresses the growing concerns of global warming and pollution by exploring more sustainable technologies, particularly electric vehicles. Structural batteries have emerged as a potential solution to overcome limitations such as low range and short autonomy in electric vehicles. The research begins with an introduction to battery components and their specifications, providing a foundation for selecting the appropriate chemistry. After analyzing the three main chemistries (lithium, sodium, and aluminum), a qualitative analysis leads to the selection of aluminum chemistry due to its lower cost, higher safety, and environmental friendliness. Carbon fiber reinforcement is chosen based on the prevalent use of carbonbased cathodes in aluminum-ion batteries. A comprehensive literature review is conducted to gain a deeper understanding of this multifunctional system and establish a basis for comparison. Several battery designs are tested before finalizing the chosen design. Detailed step-by-step descriptions of the manufacturing processes are presented, resulting in the production of various samples of the structural battery measuring 100 mm by 100 mm. The achieved results demonstrate a Young’s modulus of ˜ 19.1 GPa and a flexural strength of ˜ 247.5 MPa. Additionally, the structural battery showcased its functional capabilities by successfully illuminating different colored LEDs such as red, blue and green. Furthermore it achieved a max voltage of 1.65 V, and the capability of having constant voltage and internal resistance under a 5 mm deflection. This research contributes to the advancement of sustainable energy storage technologies and their potential application in electric vehicles. The findings highlight the successful development of an aluminum-ion structural battery with promising mechanical properties and functional performance, paving the way for further exploration in this field.