Laser additively manufactured microscale metallic lattices show great potential for high-performance applications, yet trade-offs among geometric precision, structural integrity, and computational efficiency still persist. Here, we introduce a stereolithography file format-free (STL-free) hybrid toolpath generation method for laser-based powder bed fusion (PBF-LB) that synergizes implicit geometric modeling with optimized laser scanning strategy, overcoming these limitations. By circumventing traditional mesh-based workflows, our method directly translates implicit lattice geometries into laser toolpaths while precisely regulating energy deposition trajectories. This mesh-free process enables the fabrication of complex shell lattices with ultra-thin walls and enhanced surface quality. In addition to reducing memory usage and processing time by up to 90%, the method yields a synergistic enhancement in mechanical performance, notably improving both strength and toughness. By bridging computational design and fabrication, this framework enables the scalable production of high-performance microscale lattices and unlocks their potential for industrial applications.

Large-scale renewable energy must overcome conversion and storage challenges before it can replace fossil fuels due to its intermittent nature. However, current sustainable energy devices still suffer from high cost, low efficiency, and poor service life problems. Recently, porous metal-based materials have been widely used as desirable cross-functional platforms for electrochemical and photochemical energy systems for their unique electrical conductivity, catalytic activity, and chemical stability. To tailor the porosity length scale, ordering, and compositions, 3D printing has been applied as a disruptive manufacturing revolution to create complex architected components by directly joining sequential layers into designed structures. This article intends to summarize cutting- edge advances of metal-based materials for renewable energy devices (e.g., fuel cells, solar cells, supercapacitors, and batteries) over the past decade.