Magnesium–Air Batteries: Manufacturing, Processing, Performance, and Applications

Magnesium–air (Mg–Air) batteries are emerging as a sustainable and high-energy-density solution to address the increasing global energy demands, utilizing abundant and environmentally friendly materials. This review paper examines their fundamental electrochemical mechanisms, focusing on magnesium anodes, cathode design, and electrolyte formulations. While discussing key advancements in manufacturing techniques that enhance scalability and performance, this article underscores the wide range of potential applications of Mg–Air batteries, including portable electronics, electric transportation, and off-grid energy systems. Despite persistent challenges such as anode passivation and limited rechargeability, significant progress in material engineering and process optimization is accelerating their pathway to commercialization. These developments highlight the synergy between material science and sustainable manufacturing, positioning Mg–air batteries as a promising solution for next-generation energy storage technologies.