Revolutionizing Lithium Metal Anodes With 3D-Printed Topology-Optimized Hosts for Enhanced Stability

Lithium metal anodes (LMAs) are a key material for next-generation high-energy-density batteries due to their high theoretical capacity and low electrochemical potential. However, their practical use is hindered by issues such as uncontrolled volume expansion and lithium dendrite growth, especially under deep charge/discharge cycling. In this study, a novel LMA host is designed using topology optimization, which directly links structural design with porosity and mechanical stability. Through iterative calculations, reinforced structures are developed that provide support at critical points such as the center, edges, and corners, effectively distributing stress and limiting volume changes during expansion. The topology-optimized host is fabricated using digital light processing (DLP) 3D printing, whose high resolution and accuracy make it ideal for reproducing complex microstructures. Symmetric cell tests show that the TP host/LMA system maintains stable cycling for over 1000 h under ultra-high current density (20 mA cm^{- 2}) and high capacity (20 mAh cm^{- 2}). Moreover, in full cells with a LiFePO₄ cathode, the topology-structured lithium composite anode retains 95.2% of its capacity after 150 cycles at 5 C. This work demonstrates the potential of combining topology optimization and 3D printing to create ultra-stable, high-performance LMAs, and opens a new avenue for the design of advanced batteries.