Increased electroactivity of polyaniline prior doped with lithium ions is observed during polymerization by cyclic voltammograms (CV) compared with pure polyaniline. The electrochemical performance of a three-dimensional nickel foam-supported polyaniline composite prepared by electrophoresis and a casting process was investigated at different low-vacuum pressures for casting the aforementioned slurry. An appropriate vacuum pressure of 3000 Pa was certified by cyclic voltammetry and scanning electron microscopy. The nickel foam-supported polyaniline composite cathode were prepared and observed with prohibited hydrogen evolution and the enhanced conductivity in a manganese acetate-zinc acetate solution electrolyte system with lithium ions additive. The deposited zinc anode prepared by co-electrodeposition of zinc-manganese exhibited with high discharge voltage and stable discharge platform. The zinc-manganese-deposited zinc//nickel foam-supported polyaniline composite battery exhibited significant improvement in the capacity density and cycle performance. A discharge capacity density of 142.3 mAh.g(-1) was attained by the battery, and it was maintained more than 94.7% of the original value after 60 cycles, and there was no distinct change in the coulomb efficiency with an average value of 90% over the experiment, which indicates that the present cell has promising possibility for use as an energy storage or high-performance rechargeable battery. (c) The Author(s) 2019. Published by ECS. This is an open access article distributed under the terms of the Creative Commons Attribution 4.0 License (CC BY, http://creativecommons.org/licenses/by/4.0/), which permits unrestricted reuse of the work in any medium, provided the original work is properly cited.