Programmable Chaotic Suspension Electrolysis for Scalable Manufacturing of Vacancy‐Tunable Electrolytic MnO ₂

ABSTRACT High‐performance MnO 2 for aqueous zinc‐manganese batteries (AZMBs) is still predominantly produced through laboratory‐scale syntheses that deliver low output and are difficult to scale, creating a persistent barrier to practical deployment. Here, we introduce a “programmable chaotic suspension electrolysis” strategy that incorporates nonlinear dynamics into the electrodeposition process to achieve macroscopic production of MnO 2 with precise microstructural control. Compared with conventional synthesis routes, this approach increases the MnO 2 yield by orders of magnitude. Furthermore, by regulating the aperiodic oscillations of the chaotic current, we induce abundant, tunable in situ oxygen vacancies and construct a robust γ/β intergrown tunnel framework. This distinct defect engineering significantly enhances the electrochemical activity of the material. Additionally, we establish a multi‐dimensional evaluation framework that confirms the superior thermal stability of the optimized product. Coupled with Life Cycle Assessment (LCA) and Techno‐Economic Analysis (TEA), the process demonstrates significant potential for reducing energy consumption and production costs. Overall, this work provides a generalizable pathway for the scalable manufacturing of high‐performance electrode materials and highlights the promise of chaotic electrochemistry in constructing next‐generation safe, low‐cost energy storage systems.