A novel roll-to-roll flexographic printing process for rechargeable zinc-based battery manufacturing was presented in this paper. Based on the fundamental operating mechanism of flexography, key criteria for developing functional flexographic printing inks were established, including composite ink rheology (steady-state viscosity and yield stress), ink wettability as well as ink dispersing qualities. A variety of MnO2 cathode inks were developed and analyzed comprehensively based on these criteria. A novel type of aqueous cathode ink based on PSBR polymeric binder showed excellent flexographic printability as well as promising electrochemical performance.