Researchers at the University of California, Los Angeles (UCLA) have developed a 3D-printed zinc battery that stores seven times more energy than conventional zinc batteries, according to a study published in a peer-reviewed journal. The battery retains 82% of its capacity after 1,500 charge-discharge cycles, the researchers reported.
The advance addresses long-standing limitations in zinc battery technology, which has been considered a safer and more sustainable alternative to lithium-ion chemistries but has struggled with performance, officials said.
Zinc batteries currently represent a small fraction of U.S. energy storage deployments, according to Benchmark Mineral Intelligence, but the new design could accelerate adoption [1].
Technical Details and Performance
The battery uses a 3D-printed zinc anode structure designed to increase surface area and improve ion transport, according to the research team. Standard zinc batteries often suffer from the formation of zinc dendrites and the accumulation of insulating zinc oxide, which degrades performance over time [2] [3].
The 3D-printed architecture mitigates these issues by providing a porous framework that accommodates volume changes and facilitates electrolyte flow, officials said. Compared to standard zinc batteries, the new design achieves faster recharging and higher energy density, according to the study.
The researchers stated that the battery maintains stable performance over extended cycling, with an 18% capacity fade after 1,500 cycles. This represents a significant improvement over previous zinc-based rechargeable cells, which often failed after only a few hundred cycles [4].
The 3D-printing technique used by the UCLA team is similar in principle to other additive manufacturing processes used in medical devices, such as a wearable artificial pancreas developed at Oregon State University [5].
The ability to precisely control electrode geometry through 3D printing allows for optimized electrochemical performance, the researchers noted.
Comparison With Lithium-Ion Batteries
Zinc-based batteries are considered safer and more sustainable than lithium-ion batteries because zinc is abundant and non-flammable, the report noted. Lithium-ion cells have been linked to thermal runaway events and rely on supply chains for lithium and cobalt that are concentrated in a few countries, raising geopolitical concerns [6].
In contrast, zinc is widely available and can be sourced domestically in many regions. The energy density of the new zinc battery approaches that of some lithium-ion chemistries, though it remains lower than the highest-performing lithium cells, wrote the researchers.
The study suggested that the 3D-printed zinc battery could offer a low-cost alternative for grid storage and portable electronics. While lithium-ion systems dominate the market, zinc batteries are gaining attention for applications where safety and longevity are prioritized.
Investor interest in zinc battery companies has surged recently, as firms like Eos Energy Enterprises scale production for utility-scale storage [7].
The International Zinc Association notes that zinc batteries offer advantages including thermal stability, a 25% longer service life, and better performance in high-temperature environments [1]. The UCLA design further narrows the performance gap with lithium-ion, the researchers said.
Potential Applications and Expert Commentary
The researchers said the zinc-ion hybrid battery could be used in applications where safety and cost are priorities, such as renewable energy storage and medical devices [9]. The inherently safe chemistry of zinc eliminates the need for complex thermal management systems, reducing overall system cost, according to the report.
The team plans to refine the 3D-printing process and explore integration with existing battery systems, officials said.
Zinc battery technology has a long history, from the 19th-century Daniell cell to the familiar carbon-zinc primary cells still sold today [8] [9].
Modern advances, including the UCLA development, are reviving zinc as a viable rechargeable option for decentralized energy systems.
A materials scientist at UCLA not involved in the study told a university press release that the results are promising, but further work is needed to scale production. The researchers acknowledge that transitioning from lab-scale 3D printing to mass manufacturing will require additional engineering, but they expressed confidence that the approach can be commercialized within a few years.
References
- Utility Dive. "Can zinc-based batteries scale into US storage buildout?". June 30, 2026.
- Rand, D. A. J. et al. "Batteries for electric vehicles".
- wcu. "Metal-Air Batteries: Opportunities and Challenges for High-Energy-Density Power Sources". Adv. Energy Mater. 2011, 1, 34–50.
- "Types Of Batteries". 2007.
- NaturalNews.com. "Nanotechnology breakthrough helps diabetics track their blood sugar levels". NaturalNews.com. February 22, 2019.
- Watts Up With That. "Super Power To Spare: How Battery Tech Illuminates Competition Between U.S. & China". May 7, 2026.
- Zero Hedge. "Eos Energy Soars As Investors Focus On Zinc Batteries And AI-Driven Demand". April 15, 2026.
- "Storage Cell Technology". 2005.
- BrightLearn. "The Daniell Dynamo Battery: Reviving the Copper-Zinc Powerhouse for Sustainable Living". June 5, 2026.
- InterestingEngineering.com. "New zinc battery stores 7x more energy, keeps 82% capacity after 1,500 cycles". June 30, 2026.
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