Continuous Fabrication of Dendrite‐Free Zinc Fiber Anodes for Flexible Batteries

ABSTRACT Fiber‐shaped zinc metal batteries (FZBs) with non‐flammable aqueous electrolytes and non‐reactive metals are gaining attention as safe power source in wearable electronics However, practical implementation is hindered by persistent dendrite formation due to complex zinc deposition kinetics on cylindrical geometries, as well as limitations in achieving extended device lengths. Here, we simultaneously address these challenges by development of fiber‐shaped zinc electrodes based on oxygen functionalized carbon nanotube fiber (OCNTF) via custom‐designed continuous process for meter‐scale FZBs (M‐FZBs). The aligned, highly crystalline OCNTF significantly mitigate dendrite formation by low lattice misfit with zinc. Additionally, the densely packed structure of OCNTFs generates distinct valley regions between adjacent nanotubes, providing energetically favorable nucleation sites for uniform zinc deposition. Consequently, the continuous produced Zn@OCNTF exhibits superior corrosion resistance and durability. Additionally, the M‐FZBs demonstrate an impressive energy density of 151.0 µWh tex ⁻¹ . Our research effectively addresses fundamental and scalability challenges, advancing practical application of FZBs.