Precise regulation of zinc-anode interface stresses by digital-light-processed gel polymer electrolytes for ultralong-life zinc batteries

Abstract The development of robust anode-electrolyte interfaces (AEI) with enhanced compatibility and mechanical strength is critical for regulating zinc-ion nucleation kinetics, suppressing dendrite formation, and advancing zinc-ion battery commercialization. To address persistent interface degradation during battery cycling, we propose a novel manufacturing strategy utilizing digital-light-processing (DLP) 3D printing. This approach enables programmable regulation of gel-polymer electrolyte (GPE) structures through layer-by-layer photopolymerization, achieving precision regulation of macro-microstructures and interfacial stresses. The DLP-manufactured GPEs feature cross-scale structures combining dense porous networks with smooth surface topography, providing abundant electrochemical active sites and stable interfacial contact. Multiphase-field simulations integrated with in-situ/ex-situ characterizations reveal stress-enhanced zinc deposition mechanisms, where optimized interfacial stress eliminates AEI contact instability, ensuring rapid mass transfer between electrode and electrolyte. Under regulated interface stress, the symmetrical cell demonstrates stability exceeding 2 000 hours, and the full cell retains 91.72% capacity after 8 000 ultralong cycles, with reliable operation under extreme temperature conditions (−10 ℃/60 ℃). The precise regulation of interfacial stresses establishes stable AEI configurations, demonstrating a transformative approach to durable zinc-ion battery design.