Condition-Dependent Rate Capability of Laser-Structured Hard Carbon Anodes in Sodium-Based Batteries

Changing the topography of electrodes by ultrafast laser ablation has shown great potential in enhancing electrochemical performance in lithium-ion batteries. The generation of microstructured channels within the electrodes creates shorter pathways for lithium-ion diffusion and mitigates strain from volume expansion during electrochemical cycling. The topography modification enables faster charging, improved rate capability, and the potential to combine high-power and high-energy properties. In this study, we present a preliminary exploration of this approach for sodium-ion battery technology, focusing on the impact of laser-generated channels on hard carbon electrodes in sodium-metal half-cells. The performance was analyzed by employing different conditions, including different electrolytes, separators, and electrodes with varying compaction degrees. To identify key factors contributing to rate capability improvements, we conducted a comparative analysis of laser-structured and unstructured electrodes using methods including scanning electron microscopy, laser-induced breakdown spectroscopy, and electrochemical cycling. Despite being based on a limited sample size, the data reveal promising trends and serve as a basis for further optimization. Our findings suggest that laser structuring can enhance rate capability, particularly under conditions of limited electrolyte wetting or increased electrode density. This highlights the potential of laser structuring to optimize electrode design for next-generation sodium-ion batteries and other post-lithium technologies.