Programmable Chaotic Suspension Electrolysis for Scalable Manufacturing of Vacancy-Tunable Electrolytic MnO₂

High-performance MnO₂ for aqueous zinc-manganese batteries (AZMBs) is still predominantly produced through laboratory-scale syntheses that deliver low output and are difficult to scale, creating a persistent barrier to practical deployment. Here, we introduce a "programmable chaotic suspension electrolysis" strategy that incorporates nonlinear dynamics into the electrodeposition process to achieve macroscopic production of MnO₂ with precise microstructural control. Compared with conventional synthesis routes, this approach increases the MnO₂ yield by orders of magnitude. Furthermore, by regulating the aperiodic oscillations of the chaotic current, we induce abundant, tunable in situ oxygen vacancies and construct a robust γ/β intergrown tunnel framework. This distinct defect engineering significantly enhances the electrochemical activity of the material. Additionally, we establish a multi-dimensional evaluation framework that confirms the superior thermal stability of the optimized product. Coupled with Life Cycle Assessment (LCA) and Techno-Economic Analysis (TEA), the process demonstrates significant potential for reducing energy consumption and production costs. Overall, this work provides a generalizable pathway for the scalable manufacturing of high-performance electrode materials and highlights the promise of chaotic electrochemistry in constructing next-generation safe, low-cost energy storage systems.