Designing vertical aligned Zn microchannels for enhanced performance of Zn metal anodes

Aqueous zinc-ion batteries hold significant promise for grid-scale energy storage due to their inherent safety, cost-effectiveness, and environmental compatibility. However, their practical deployment remains hindered by persistent challenges, including uncontrolled zinc dendrite formation and non-uniform metal deposition during repeated cycling. In this study, we propose a laser-etched zinc metal anode featuring vertically aligned, uniformly distributed pores (LVAZn) to address these limitations. By systematically tuning pore dimensions and spacing within the LVA-Zn microchannels, we demonstrate precise control over zinc deposition behavior. The vertical microchannels architecture homogenizes electric field distribution, lowering localized current density and guiding zinc to deposit preferentially within the pores rather than on the electrode surface. Furthermore, a polyimide coating applied to the anode surface mitigates parasitic reactions by shielding zinc from direct electrolyte contact. Symmetrical cells incorporating the optimized LVA-Zn anode exhibit exceptional cycling stability across a broad range of current densities (0.2–5 mA cm⁻²), maintaining stable voltage profiles with minimal polarization (30 mV at 5 mA cm⁻²). When integrated with MnO₂ cathodes in full-cell configurations, the system achieves a high reversible capacity of 270 mAh g⁻¹ and retains 98 % of its initial capacity after 300 cycles at 1 A g⁻¹. These results highlight the synergistic benefits of structural engineering and interface modification in advancing durable, high-performance zinc-based energy storage systems.