A battery case shaping apparatus and method shape a pouch-shaped battery case. The battery case shaping apparatus includes a conductive liquid and positive and negative electrodes each configured to generate electric discharge in the conductive liquid in order to prevent a laminate sheet for battery cases from being damaged by friction between a punch and a die and to allow the entirety of the laminate sheet to be elongated.

A method of using high push force to fabricate a composite material containing carbon material comprises steps placing a substrate in a carbon material-containing dispersion including a carbon material, and letting one surface of the substrate contact the carbon material-containing dispersion; and providing a high push force range between 300 G and 3000 G to the carbon material-containing dispersion to push the carbon material-containing dispersion and make the carbon material enter the substrate to form a composite material containing the carbon material.

A method of forming channels within a substrate includes: (a) molding a sacrificial component directly into the substrate; (b) igniting the sacrificial component to cause a deflagration of the sacrificial component, thereby forming a channel in the substrate; and (c) cleaning the channel in the substrate to remove byproducts of the deflagration of the sacrificial component. The sacrificial component includes a combustible material with a protective shell, and the substrate includes a polymeric material.

A method of forming channels within a substrate includes: (a) molding a sacrificial component directly into the substrate; (b) igniting the sacrificial component to cause a deflagration of the sacrificial component, thereby forming a channel in the substrate; and (c) cleaning the channel in the substrate to remove byproducts of the deflagration of the sacrificial component. The sacrificial component includes a combustible material with a protective shell, and the substrate includes a polymeric material.

Disclosed embodiments include the formation of an article of manufacture by a process in which vibrations are generated in a bulk material disposed within a build chamber. The vibrations are focused within a section of the base material, and the focusing is controlled to cause the section of the base material to undergo a physical transformation to form at least a portion of the article of manufacture.