NOVELTY - Fabricating electrical-energy-storage unit (EESU) components involves screen-printing a flat Teflon (RTM; polytetrafluoroethylene) plastic-coated stainless steel plate with an ink containing alumina-coated composition-modified barium titanate ceramic powder, poly(ethylene terephthalate) plastic powder and a binder.    USE - For fabricating electrical-energy-storage unit components (claimed) useful in e.g. electric vehicles, buses, bicycles, tractors, device for transportation or performing work, portable tools, portable computers, storing electrical power generated from electrical energy generating plants, solar voltaic cells, wind-powered electrical energy generating units, or other alternative sources on the utility grids for residential, commercial or industrial applications.    ADVANTAGE - The process provides a lightweight electrical-energy-storage unit (EESU) having the capability to store ultrahigh amounts of energy (upto 52.22 kW.h). The EESU has a total weight of 281.56 pounds which includes covers, connectors and associated hardware and a volume of 4541 inch3. The components have the capability to withstand 1000000 full voltage cycles of 3500 - 0 V, then back to 3500 V without degrading the leakage, capacitance or voltage breakdown capabilities of the components. Plastic matrix assists in lowering the sintering temperature to 150degreesC and hot-isostatic-pressing temperatures to 180degreesC and the required pressure to 100 bar, eliminating the use of very expensive platinum, palladium, palladium-silver alloy, or costly nickel powders as the terminal metal.    DETAILED DESCRIPTION - Fabricating electrical-energy-storage unit (EESU) components involves: a) cooling poly(ethylene terephthalate) plastic pellets to -150degreesC by air products process cooling system which transports the material to the jet pulverizing unit; b) feeding the pellets in micron-master jet pulverizing mill and pulverizing to submicron size; c) cooling aluminum powders to -150degreesC by the air products process cooling system which transports the material to the jet pulverizing unit; d) feeding aluminum powder into the micron-master jet pulverizing mill and pulverizing to submicron size; e) preparing a screen-printing ink containing alumina-coated composition-modified barium titanate ceramic powder, poly(ethylene terephthalate) plastic powder and binder (b1) consisting of the lowest-decomposition-temperature resin; nitrocellulose and two solvents for the resin; glycerol and isopropyl alcohol (where the former is more viscous than the latter, so that the proper screen-printing rheology can be easily adjusted); f) preparing a screen-printing ink containing poly(ethylene terephthalate) plastic powder and the binder (b1) (where former is more viscous than the latter, so that the proper screen-printing rheology can be easily adjusted); g) preparing a screen-printing ink containing aluminum metal powder and the binder (b1) (where the former is more viscous than the latter, so that the proper screen-printing rheology can be easily adjusted); h) mixing each ink independently in a plastic tank mechanically, providing ultrasonic agitation, and high-impact multiple oppositely directed streams to give a well-dispersed ink free of agglomerates; i) delivering each ink independently from its mixing tank to the appropriate stations of the screen-printing system via high-pressure pumps to a line manifold with several equal-spaced holes located at the edge of each printing screen which distributes the ink uniformly at this edge due to the high pressure and the hole size causing all of the pressure drop to occur at the manifold hole exits; j) screen-printing a basis layer of the poly(ethylene terephthalate) plastic powder and binder on a flat Teflon (RTM; polytetrafluoroethylene) plastic-coated stainless steel plate; k) screen-printing a second layer comprised of aluminum powder and binder via a stencil for the electrodes; l) screen-printing a layer of poly(ethylene terephthalate) plastic powder and binder via a stencil on the first layer as part of the second layer and surrounding the electrode layer on three of its sides; m) screen-printing a third layer (serves as active dielectric layer) of alumina-coated composition-modified barium titanate power, poly(ethylene terephthalate) plastic powder, and binder via a stencil on the second layer; n) screen-printing a layer of poly(ethylene terephthalate) plastic powder and binder via a stencil onto the second layer as part of third layer and surrounding the active dielectric layer on all four sides; o) screen-printing a fourth layer of aluminum powder and binder via a stencil onto the third layer, (the fourth layer serving as the opposite electrode to the active dielectric layer); p) screen-printing a layer of poly(ethy1ene terephthalate) plastic powder and binder via a stencil onto the third layer as part of the fourth layer and surrounding the electrode layer on three of its sides; q) repeating the collection of steps from j) - o) 100 times to fabricate elements; r) processing after each screen-printing step the Teflon plastic-coated stainless steel plate containing deposited green sheet by an inline oven having temperature zone of 40 - 150degreesC at a speed such that the through time are 10 seconds for the electrode layers and 60 seconds for the dielectric layers that allow binder-burnout and sintering to be completed without destructively cracking or rupturing the layers; s) dicing the multilayer screen-printed sheets into individual elements with dimensions of 0.508/1.143 cm; t) placing the elements into indentations of Teflon trays and then inserting into the hot isostatic pressing oven and processing at 180degreesC and at a pressure of 100 bar for 45 minutes; u) binding ten elements together with an adhesive having a curing temperature of 80degreesC for 10 minutes and creating a component; v) abrasively cleaning the component to expose the alternately offset interleaved aluminum electrodes to each of the two opposite sides of the component and binding a high-conductivity silver-loaded elastomeric epoxy resin paste to the aluminum end caps to the component sides that have the exposed electrodes; w) placing the components into an oven and ramping the temperature to 180degreesC for 20 minutes and then applying +2000 V to the anode and -2000 V to the cathode for 5 minutes (after completion of the process, the alumina-coated composition-modified barium titanate powder is dispersed within the poly(ethylene terephthalate) plastic matrix and fully polarized); x) assembling the components into a first level array; y) stacking a number of arrays on top of one another in accordance with the packaging requirement until a sufficient number of arrays are stacked to obtain the desired energy storage of the EESU; and z) packaging the array stack in the final EESU assembly where all the cells are arranged in a parallel configuration.