• Mesopore spatial distribution in HZSM-5 significantly influences both zinc state and product distribution in 1-hexene aromatization.
• Interior mesopores enhance xylene selectivity by 12.4% compared to conventional Zn-loaded parent HZSM-5 at >99% conversion.
• Evenly distributed mesopores prolong catalyst lifetime but reduce aromatics selectivity due to micropore damage near the surface.
• Synergy between mesopore spatial distribution and optimized acid properties is key to improving high-value xylene yield.