Abstract
Sodium-ion batteries have been attracting extensive attention in both academic and industrial fields. However, the lack of large-area and ultrathin sodium (Na) metal foil hinders basic research on and commercialization of energy-dense Na-ion batteries. Here we successfully fabricated a metre-length, ultrathin (≤50 μm), mechanically strengthened Na metal foil by a roll-to-roll calendaring process with interfacial lubrication and functional modification. By developing self-lubricating polydimethylsiloxane as the multifunctional agent, the poor processibility of metallic Na is addressed by forming a mechanically strong interface as well as a surface lubricant film during rolling. Furthermore, polydimethylsiloxane-derived (Si–O)n-Na interphases can guide Na+-ion interfacial diffusion and enable a robust solid electrolyte interphase. Consequently, the large-area ultrathin Na foil exhibits a stable electrode potential and stripping capacity, as well as prolonged lifespan compared with bare Na anodes. This approach enables the realization of amp-hour-level Na metal pouch cells under a low negative-to-positive capacity ratio of 1.9, showing an energy density of 180.2 Wh kg−1. This scalable ultrathin Na foil establishes a materials foundation for fundamental studies on Na-ion batteries and the potential manufacture of high-energy-density Na metal batteries.
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Acknowledgements
We thank L. Gu and T. Lin of Tsinghua University for data analysis and discussion. This research was supported by the high performanced computing resource and Analysis and Testing Center at Beihang University. We acknowledge the technicians at Shenzhen HUASUAN Technology Co., Ltd. for assistance with finite element calculations (https://huasuankeji.com). This work was supported by the International Cooperation Project of National Key Research and Development Program of China (grant nos. 2020YFA0710403 to L.G. and 2022YFE0126300 to H.W.), National Natural Science Foundation of China (grant nos. 52225208 to X.T.; 12374284, 52172178 and 52302287 to H.W.; 52494930 and 52450002 to L.G.; 52222317 to J.N.; and 52302287 to J.W.).
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M.T., H.W. and L.G. conceived the idea. M.T., S.D., J.W. and H.L. cowrote the manuscript. M.T., S.D., J.Z., L.C. and H.L. designed and performed the experiments and analysed the data. K.Y., S.S., Y.L., J.N. and X.T. assisted in cryo-TEM characterizations for materials. Q.Z. performed the density functional theory calculation. R.L. and R.W. contributed to AFM characterizations for materials. P.C. assisted in the fabrication of Na foils in Jiaxing Changgao New Material Technology Co., LTD. M.T., L.W., B.Z. and D.Y. provided pouch cells. W.L. and X.W. performed the SEM characterization. All authors discussed the results.
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Nature Synthesis thanks Kaifu Huo, Soojin Park and the other, anonymous, reviewer(s) for their contribution to the peer review of this work. Primary Handling Editor: Peter Seavill, in collaboration with the Nature Synthesis team.
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Supplementary Figs. 1–53, Tables 1–7, Videos 1–4 and References 1–22.
Supplementary Video 1
FE simulations of the thinning process of Na foils with and without lubricating oil.
Supplementary Video 2
Air stability tests of p-Na and Na in dry condition.
Supplementary Video 3
Air stability tests of p-Na and Na in humid condition.
Supplementary Video 4
Roll-to-roll fabrication of meter-scale ultrathin Na metal foils.
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Tang, M., Dong, S., Yue, K. et al. Scalable ultrathin sodium metal anodes. Nat. Synth (2025). https://doi.org/10.1038/s44160-025-00934-0
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DOI: https://doi.org/10.1038/s44160-025-00934-0
