Hierarchical Dendrite-Trapping 3D-Printed Polymer-Coated Zn Anode toward Ultra-Stable Cycling at High Current Densities

Aqueous zinc-ion batteries (AZIBs) have attracted considerable interest as viable substitutes for lithium-ion batteries. To meet the demand for customizable and geometrically complex electronics, zinc powder-based anodes are increasingly replacing conventional zinc foil anodes. However, zinc powder-based anodes face critical challenges in practical deployment, including accelerated corrosion and exacerbated dendrite formation compared to zinc foil anodes. This work presents a 3D-printed, high-safety zinc powder-based anode with a poly(ethylene glycol) (PEG)-coated layer. The 3D anode can trap dendrites and enhance battery energy density. The PEG coating not only suppresses the hydrogen evolution reaction (HER) but also regulates Zn²⁺ deposition/stripping through uniform electric field distribution. The 3D Zn@PEG anode demonstrates an outstanding deposition/stripping capability, high-rate performance, and prolonged cycling stability. This strategy provides a scalable and cost-effective approach to developing dendrite-resistant zinc-ion batteries. Moreover, this method holds great potential for industrial-scale electrode production.