Three-Dimensional Structural Engineering of Zn Anodes for Advanced Aqueous Zinc-Ion Batteries: Mechanisms, Challenges, and Prospects

Abstract Benefiting from their intrinsic safety, earth-abundant zinc resources, low manufacturing cost, and environmentally benign chemistry, aqueous zinc-based batteries have emerged as a compelling candidate for next-generation sustainable energy storage systems. Although metallic Zn anodes offer a high theoretical capacity and an advantageous redox potential, their practical application is severely hindered by interfacial instability issues, including dendritic growth, dead-Zn formation, hydrogen evolution, and corrosion, leading to poor Coulombic efficiency and limited cycling durability. While extensive research has focused on materials-level optimization, the translation of lab-scale advances into commercially viable devices hinges on scalable and controllable manufacturing technologies. In this review, we address this gap by presenting a manufacturing-centric analysis of three-dimensional (3D) Zn anode engineering. We systematically evaluate how advanced manufacturing processes, including additive manufacturing, laser ablation, electrospinning, template imprinting, and electrodeposition, enable precise regulation of electrode architecture, local electric fields, and Zn2+ transport pathways. These advantages collectively promote uniform Zn plating/stripping, suppress dendrite growth, and alleviate parasitic side reactions. This review provides a systematic overview of recent progress in topology-guided 3D Zn anodes, encompassing representative fabrication strategies. Furthermore, structure-performance relationships across various 3D designs are elucidated. Finally, we outline remaining challenges and future research directions toward durable, scalable, and high-performance zinc-based energy storage.