diff --git a/tests/test_protocol_on_cpu.py b/tests/test_protocol_on_cpu.py
index 099fde53a3f..1874e834f0a 100644
--- a/tests/test_protocol_on_cpu.py
+++ b/tests/test_protocol_on_cpu.py
@@ -779,6 +779,217 @@ def test_from_tensordict():
     assert data.meta_info["name"] == "abdce"
 
 
+@pytest.mark.skipif(
+    parse_version(tensordict.__version__) < parse_version("0.10"), reason="requires at least tensordict 0.10"
+)
+def test_to_tensordict_with_nested_lists():
+    """Test converting DataProto with nested lists to TensorDict (lists of lists)."""
+    obs = torch.tensor([1, 2, 3])
+    # Simulate turn_scores or tool_rewards: array of lists with varying lengths
+    turn_scores = [[], [0.5, 0.8], [0.9]]
+
+    data = DataProto.from_dict(tensors={"obs": obs}, non_tensors={"turn_scores": turn_scores})
+
+    # This should not raise an error
+    tensordict_output = data.to_tensordict()
+
+    # Verify the data is preserved
+    assert torch.all(torch.eq(tensordict_output["obs"], obs)).item()
+    # Verify nested structure is accessible (TensorDict wraps NonTensorStack as LinkedList)
+    retrieved_scores = tensordict_output["turn_scores"]
+    assert len(retrieved_scores) == len(turn_scores)
+    # Verify content matches
+    assert list(retrieved_scores[0]) == []
+    assert list(retrieved_scores[1]) == [0.5, 0.8]
+    assert list(retrieved_scores[2]) == [0.9]
+
+
+@pytest.mark.skipif(
+    parse_version(tensordict.__version__) < parse_version("0.10"), reason="requires at least tensordict 0.10"
+)
+def test_to_tensordict_with_nested_dicts():
+    """Test converting DataProto with lists of dicts to TensorDict."""
+    obs = torch.tensor([1, 2, 3])
+    # Simulate reward_extra_info: array of dicts
+    reward_extra_info = [{"acc": 1.0}, {"acc": 0.0}, {"acc": 1.0}]
+
+    data = DataProto.from_dict(tensors={"obs": obs}, non_tensors={"reward_extra_info": reward_extra_info})
+
+    # This should not raise an error - this was the original bug
+    tensordict_output = data.to_tensordict()
+
+    # Verify the data is preserved
+    assert torch.all(torch.eq(tensordict_output["obs"], obs)).item()
+    # Verify nested dicts are accessible
+    retrieved_info = tensordict_output["reward_extra_info"]
+    assert len(retrieved_info) == len(reward_extra_info)
+    # Verify content matches
+    for i, expected_dict in enumerate(reward_extra_info):
+        assert dict(retrieved_info[i]) == expected_dict
+
+
+@pytest.mark.skipif(
+    parse_version(tensordict.__version__) < parse_version("0.10"), reason="requires at least tensordict 0.10"
+)
+def test_to_tensordict_with_complex_nested_structures():
+    """Test converting DataProto with complex nested structures (lists of lists of dicts)."""
+    obs = torch.tensor([1, 2, 3])
+    # Simulate raw_prompt: array of lists containing dicts
+    raw_prompt = [
+        [{"content": "Question 1", "role": "user"}],
+        [{"content": "Question 2", "role": "user"}, {"content": "Answer 2", "role": "assistant"}],
+        [{"content": "Question 3", "role": "user"}],
+    ]
+
+    data = DataProto.from_dict(tensors={"obs": obs}, non_tensors={"raw_prompt": raw_prompt})
+
+    # This should not raise an error
+    tensordict_output = data.to_tensordict()
+
+    # Verify the data is preserved
+    assert torch.all(torch.eq(tensordict_output["obs"], obs)).item()
+    # Verify complex nested structure is accessible
+    retrieved_prompt = tensordict_output["raw_prompt"]
+    assert len(retrieved_prompt) == len(raw_prompt)
+    # Spot check: verify first prompt has correct structure
+    assert len(retrieved_prompt[0]) == 1
+    assert dict(retrieved_prompt[0][0]) == {"content": "Question 1", "role": "user"}
+
+
+@pytest.mark.skipif(
+    parse_version(tensordict.__version__) < parse_version("0.10"), reason="requires at least tensordict 0.10"
+)
+def test_to_tensordict_and_back_with_nested_data():
+    """Test round-trip conversion: DataProto → TensorDict → DataProto with nested structures."""
+    obs = torch.tensor([1, 2, 3, 4])
+    labels = ["a", "b", "c", "d"]
+
+    # Multiple types of nested structures
+    turn_scores = [[], [0.5], [0.8, 0.9], [0.7]]
+    reward_extra_info = [
+        {"acc": 1.0, "loss": 0.1},
+        {"acc": 0.5, "loss": 0.3},
+        {"acc": 1.0, "loss": 0.05},
+        {"acc": 0.0, "loss": 0.9},
+    ]
+    raw_prompt = [
+        [{"content": "Q1", "role": "user"}],
+        [{"content": "Q2", "role": "user"}],
+        [{"content": "Q3", "role": "user"}, {"content": "A3", "role": "assistant"}],
+        [{"content": "Q4", "role": "user"}],
+    ]
+
+    # Create original DataProto
+    original_data = DataProto.from_dict(
+        tensors={"obs": obs},
+        non_tensors={
+            "labels": labels,
+            "turn_scores": turn_scores,
+            "reward_extra_info": reward_extra_info,
+            "raw_prompt": raw_prompt,
+        },
+        meta_info={"experiment": "test_nested"},
+    )
+
+    # Convert to TensorDict
+    tensordict_output = original_data.to_tensordict()
+
+    # Convert back to DataProto
+    reconstructed_data = DataProto.from_tensordict(tensordict_output)
+
+    # Verify tensors are preserved
+    assert torch.all(torch.eq(reconstructed_data.batch["obs"], obs)).item()
+
+    # Verify non-tensor data is preserved
+    assert reconstructed_data.non_tensor_batch["labels"].tolist() == labels
+
+    # Verify nested structures are preserved
+    assert len(reconstructed_data.non_tensor_batch["turn_scores"]) == len(turn_scores)
+    for orig, recon in zip(turn_scores, reconstructed_data.non_tensor_batch["turn_scores"], strict=True):
+        assert list(orig) == list(recon)
+
+    assert len(reconstructed_data.non_tensor_batch["reward_extra_info"]) == len(reward_extra_info)
+    for orig, recon in zip(reward_extra_info, reconstructed_data.non_tensor_batch["reward_extra_info"], strict=True):
+        assert orig == recon
+
+    assert len(reconstructed_data.non_tensor_batch["raw_prompt"]) == len(raw_prompt)
+    for orig, recon in zip(raw_prompt, reconstructed_data.non_tensor_batch["raw_prompt"], strict=True):
+        assert orig == list(recon)
+
+    # Verify meta_info is preserved
+    assert reconstructed_data.meta_info["experiment"] == "test_nested"
+
+
+@pytest.mark.skipif(
+    parse_version(tensordict.__version__) < parse_version("0.10"), reason="requires at least tensordict 0.10"
+)
+def test_to_tensordict_agent_loop_scenario():
+    """Test the exact scenario from agent loop: DataProto with tool rewards, acc, etc.
+
+    This test reproduces the exact error from the agent loop where nested structures
+    (lists of lists, lists of dicts) failed to convert to TensorDict.
+    """
+    # Simulate real agent loop data structure
+    prompts = torch.tensor([[1, 2, 3], [4, 5, 6]])
+    responses = torch.tensor([[7, 8], [9, 10]])
+
+    # Non-tensor data with nested structures from agent loop
+    data_source = ["lighteval/MATH", "lighteval/MATH"]
+    uid = ["uuid-1", "uuid-2"]
+    num_turns = np.array([2, 4], dtype=np.int32)
+    acc = np.array([1.0, 0.0])
+    turn_scores = [[], [0.5, 0.8]]  # Lists of varying lengths
+    reward_extra_info = [{"acc": 1.0}, {"acc": 0.0}]  # List of dicts
+    raw_prompt = [
+        [{"content": "Compute 4 @ 2", "role": "user"}],
+        [{"content": "Compute 8 @ 7", "role": "user"}],
+    ]
+    tool_rewards = [[0.0], []]  # List of lists
+
+    data = DataProto.from_dict(
+        tensors={"prompts": prompts, "responses": responses},
+        non_tensors={
+            "data_source": data_source,
+            "uid": uid,
+            "num_turns": num_turns,
+            "acc": acc,
+            "turn_scores": turn_scores,
+            "reward_extra_info": reward_extra_info,
+            "raw_prompt": raw_prompt,
+            "tool_rewards": tool_rewards,
+        },
+        meta_info={"global_steps": 42},
+    )
+
+    # THE KEY TEST: This should not raise ValueError about TensorDict conversion
+    tensordict_output = data.to_tensordict()
+
+    # Verify tensors are accessible
+    assert torch.all(torch.eq(tensordict_output["prompts"], prompts)).item()
+    assert torch.all(torch.eq(tensordict_output["responses"], responses)).item()
+
+    # Verify all nested structures are accessible (content check, not type check)
+    assert len(tensordict_output["turn_scores"]) == 2
+    assert list(tensordict_output["turn_scores"][0]) == []
+    assert list(tensordict_output["turn_scores"][1]) == [0.5, 0.8]
+
+    assert len(tensordict_output["reward_extra_info"]) == 2
+    assert dict(tensordict_output["reward_extra_info"][0]) == {"acc": 1.0}
+
+    assert len(tensordict_output["raw_prompt"]) == 2
+    assert dict(tensordict_output["raw_prompt"][0][0]) == {"content": "Compute 4 @ 2", "role": "user"}
+
+    assert len(tensordict_output["tool_rewards"]) == 2
+    assert list(tensordict_output["tool_rewards"][0]) == [0.0]
+    assert list(tensordict_output["tool_rewards"][1]) == []
+
+    # Verify round-trip conversion works perfectly
+    reconstructed = DataProto.from_tensordict(tensordict_output)
+    assert len(reconstructed) == 2
+    assert reconstructed.meta_info["global_steps"] == 42
+    assert torch.all(torch.eq(reconstructed.batch["prompts"], prompts)).item()
+
+
 def test_serialize_deserialize_single_tensor():
     """Test serialization and deserialization of a single tensor"""
     # Create test tensor
diff --git a/verl/protocol.py b/verl/protocol.py
index e0b1affe8f1..53d291b1fe6 100644
--- a/verl/protocol.py
+++ b/verl/protocol.py
@@ -1118,6 +1118,8 @@ def to_tensordict(self) -> TensorDict:
         tensor_batch = self.batch.to_dict()
         non_tensor_batch = self.non_tensor_batch
 
+        from tensordict.tensorclass import NonTensorData, NonTensorStack
+
         from verl.utils import tensordict_utils as tu
 
         common_keys = set(tensor_batch.keys()) & set(non_tensor_batch.keys())
@@ -1125,7 +1127,8 @@ def to_tensordict(self) -> TensorDict:
 
         for key, val in non_tensor_batch.items():
             assert isinstance(val, np.ndarray)
-            tensor_batch[key] = val.tolist()
+            # Convert to NonTensorStack instead of plain list to handle nested structures
+            tensor_batch[key] = NonTensorStack.from_list([NonTensorData(item) for item in val])
         output = tu.get_tensordict(tensor_dict=tensor_batch, non_tensor_dict=self.meta_info)
         return output
 
diff --git a/verl/utils/tensordict_utils.py b/verl/utils/tensordict_utils.py
index fb26f27c8fb..25f828dbce7 100644
--- a/verl/utils/tensordict_utils.py
+++ b/verl/utils/tensordict_utils.py
@@ -110,6 +110,17 @@ def get_tensordict(tensor_dict: dict[str, torch.Tensor | list], non_tensor_dict:
         if isinstance(val, torch.Tensor) and val.is_nested:
             assert val.is_contiguous(), "Nested tensors must be contiguous. Try setting layout=torch.jagged"
 
+        # Skip validation for NonTensorStack as it's already properly formatted
+        if isinstance(val, NonTensorStack):
+            if batch_size is None:
+                batch_size = len(val)
+            else:
+                assert len(val) == batch_size, (
+                    f"Batch size of NonTensorStack {key} is not consistent with other tensors. "
+                    f"Expected {batch_size}, got {len(val)}"
+                )
+            continue
+
         if isinstance(val, list):
             for v in val:
                 assert not isinstance(v, torch.Tensor), (