A Comprehensive Review on Layered Oxide Cathodes for Sodium‐Ion Batteries: Design, Manufacturing, and Commercialization

ABSTRACT Layered oxide cathodes are among the most promising candidates for sodium‐ion batteries (SIBs), offering high capacity, versatile structures, and a compelling cost outlook. However, their journey from laboratory research to widespread commercial use is hampered by a complex set of scientific and engineering challenges. This review provides a comprehensive, cross‐disciplinary analysis of this journey, connecting material design with scalable manufacturing and real‐world market viability. We first establish a foundation by examining the structural polymorphism, degradation mechanisms, and rational element selection that govern cathode performance. The discussion then transitions to industrial production, critically evaluating scalable synthesis methods like coprecipitation, spray drying, and solid‐state reactions, with a focus on reproducibility, cost, and key scaling challenges. Moving to cell‐level integration, we address full‐cell design considerations—including hard carbon anode compatibility, pre‐sodiation strategies, and cell formatting—alongside critical failure modes such as gas generation and thermal runaway. Finally, we situate these technological advances within the broader commercial landscape, analyzing cost structures, emerging application niches, and the evolving policy environment. By synthesizing insights across the entire value chain, this work aims to serve as a strategic guide for researchers and industry professionals working to translate layered oxide cathodes from promising materials into practical, sustainable energy storage solutions.