Deposition of reactive metals with protection layer for high volume manufacturing

A method, comprising:

• forming a molten material, the forming comprising:
• delivering a porous material to a container operable to hold the porous material, wherein the container has a first connection and a second connection disposed on the container;
• supplying power from a power source to the first connection and the second connection disposed on the container to heat the container by direct current;
• and
• forming the molten material by heating the porous material by direct current to a temperature greater than 1,000 degrees Celsius;
• delivering a transfer liquid to a curved quenching surface of a rotating casting drum;
• forming a material layer stack over the curved quenching surface of the rotating casting drum and the transfer liquid, comprising:
• forming a first layer on the transfer liquid;
• forming a second layer on the first layer, wherein the first layer or the second layer is the molten material;
• and
• transferring the material layer stack from the rotating casting drum to a continuous flexible substrate.