3D-printed pillar array pore ceramic membrane for high areal capacity zinc-based flow battery

Zinc-based flow batteries (ZFBs) are promising for large-scale energy storage applications. However, the formation of Zn dendrites and the limited areal capacity of ZFBs hinder their further development. In this study, we designed a digital light-processed 3D-printed pillar array pore ceramic membrane (3DPC) to construct ZFBs with high areal capacity and long cycle life. The pillar array pore design reduces the transmembrane resistance by ~60% and facilitates K⁺ and Na⁺ transport. The pore arrays serve as electrolyte reservoirs to regulate interfacial ion distribution and provide sufficient space for Zn deposition. Moreover, the surface hardness of the ceramics up to 1.46 GPa provides resistance against zinc dendrite damage. Furthermore, the cell based on the designed 3DPC exhibits a stable energy efficiency exceeding 79% during operation for over 950 h at an areal capacity of 280 mAh cm⁻². This study demonstrates the promising potential of 3D-printed ceramic membranes for metal-based flow batteries.