Solid-State Batteries Move Closer to Mass Production as Global Manufacturers Ramp Up Pilot Production

Solid-state batteries (SSBs) are rapidly advancing toward commercialization, with major companies like Toyota, Nissan, and Samsung SDI beginning pilot production and targeting GWh-level output by 2027. These batteries promise enhanced safety and higher energy density, yet face significant challenges related to high production costs and complex manufacturing processes. Despite these hurdles, manufacturers are progressing towards cost reductions through scaling, with TrendForce projecting costs to fall to USD 0.084–0.098 per Wh by 2035. Japanese companies, led by Toyota, are pushing for early mass production by 2026, while Chinese and South Korean firms follow closely, seeking to meet domestic demand for electric vehicles and energy storage.

Read more (https://www.trendforce.com/presscenter/news/20241031-12346.html)

SSBs are advancing towards commercialization as companies like Toyota, Nissan, and Samsung SDI begin pilot production, aiming to achieve GWh-level output by 2027. SSBs promise higher safety and energy density but face hurdles in production cost, complex manufacturing, and supply chain immaturity. Currently, semi-solid-state batteries, which have achieved GWh-scale deployment in EVs, cost over CNY 1/Wh (≈ USD 0.14/Wh), but TrendForce expects costs to drop below CNY 0.4/Wh (≈ USD 0.056/Wh) by 2035 with production advancements. All-solid-state batteries (ASSBs), progressing from prototypes to engineering-scale production, may see prices fall to CNY 0.6–0.7/Wh (≈ USD 0.084–0.098/Wh) by 2035 if demand scales above 10 GWh. Sulfide-based SSBs are particularly promising due to their high ionic conductivity, attracting major manufacturers despite challenges with cost and moisture sensitivity. Though current SSBs are not yet competitive with liquid lithium-ion batteries, TrendForce predicts cost reductions through scaling and strong government and capital support.

Among the leading manufacturers of all-solid-state batteries (ASSBs), several companies are targeting mass production (MP) status by the late 2020s. Toyota from Japan is poised to be one of the earliest, planning to reach mass production by 2026, setting a rapid pace in the industry. Samsung SDI and SK On from South Korea are also aiming for mass production by 2027, along with Chinese companies like CATL and BYD, who are likewise on track for MP status around the same period. This timeline highlights a competitive landscape where Japanese and South Korean firms are pushing for an earlier rollout, while Chinese companies are closely following, aiming to capitalize on their domestic market’s significant demand for electric vehicles and energy storage. Japan’s early push, led by Toyota, suggests a strategic approach to secure a leadership position in advanced battery technology.

Atomic Layer Deposition (ALD) has become crucial for advancing solid-state batteries due to its ability to create uniform, pinhole-free, and conformal thin films on complex structures. For solid-state electrolytes (SSEs), ALD enables the deposition of materials like lithium phosphorus oxynitride (LiPON) with high ionic conductivity, which enhances overall battery performance by forming thin, conformal electrolyte layers. This technology also plays a significant role in interface engineering by modifying the interfaces between electrodes and electrolytes. ALD-deposited interlayers improve chemical compatibility, reduce interfacial resistance, and suppress unwanted reactions, thereby improving the durability and efficiency of solid-state batteries.

ALD is especially beneficial for the development of 3D battery architectures, where its conformal coating capability enables uniform deposition on high-aspect-ratio structures, increasing surface area and enhancing energy and power densities. In addition, ALD is used to apply protective coatings to electrode materials, which prevents degradation and enhances battery stability. Examples include ALD-grown lithium silicate films that serve as solid-state electrolytes with reliable ionic conductivity. Recent research highlights ALD’s essential role in producing high-performance ASSBs and SSBs, focusing on thin-film deposition precision and interface engineering to overcome challenges related to solid-state battery design and performance.

Key applications of ALD in sulfur-based SSBs include protective coatings on sulfur cathodes, enhancing solid electrolytes, and interface engineering. ALD can apply ultra-thin, conformal coatings on sulfur cathodes, which help to mitigate polysulfide dissolution—a common issue in sulfur-based systems that leads to capacity fading. By creating a barrier layer, ALD coatings help to prevent polysulfides from migrating, thereby enhancing cycle life and reducing degradation. For example, materials like Al2O3 and TiO2 deposited via ALD have been used to form stable interfacial layers that suppress undesirable reactions.

ALD is also utilized to improve the ionic conductivity of sulfide-based solid electrolytes, such as Li2S-P2S5, which are promising due to their high ionic conductivity and similarity to liquid electrolytes. ALD can deposit thin films of stabilizing materials on these electrolytes to prevent reactions with lithium and improve stability. Additionally, ALD helps create protective layers around sulfide electrolytes, which are highly sensitive to moisture and oxygen, reducing the need for stringent environmental controls.

Interface engineering is another important application of ALD, with the precision of ALD enabling the deposition of thin interlayers at the electrode-electrolyte interfaces, addressing the issue of poor contact and high interfacial resistance in sulfur-based SSBs. These interlayers help to form a stable “solid-solid” contact, minimizing interfacial impedance and enhancing ion transfer across the interface. Materials such as lithium phosphorous oxynitride (LiPON) or lithium silicate are often used in ALD processes to create these interlayers, leading to improved overall battery performance and stability.

Refernces:

https://www.frontiersin.org/journals/energy-research/articles/10.3389/fenrg.2018.00010/full

https://pubs.rsc.org/en/content/articlelanding/2021/na/d0na01072c

https://www.frontiersin.org/journals/energy-research/articles/10.3389/fenrg.2018.00010/full

https://www.eng.uwo.ca/nanoenergy/publications/2017/PDFs/Atomic-Layer-Deposited-Lithium-Silicates-as-Solid-State-Electrolytes-for-All-Solid-State-Batteries.pdf

GM Ventures Invests $10 Million in Forge Nano to Boost EV Battery Technology with Atomic Armor

GM Ventures, the venture arm of General Motors, recently invested $10 million in Forge Nano, a materials science company known for its advanced battery technology. Forge Nano specializes in Atomic Layer Deposition (ALD), particularly its "Atomic Armor" technology, which enhances battery materials by applying ultra-thin coatings. This innovation improves the performance, lifespan, and charging speed of electric vehicle (EV) batteries. 

“GM Ventures’ primary goal is to bring disruptive technology into the GM ecosystem to improve products and processes,” said Anirvan Coomer, managing director of GM Ventures. “Forge Nano’s Atomic Armor technology has game-changing potential for our battery materials at significant scale. They have already demonstrated the ability to expand cathode capabilities, which is the most expensive battery cell component. This could unlock benefits for customers and the business.”

The investment is part of GM's broader strategy to secure a robust supply chain for its EVs, and the partnership will focus on optimizing battery cathode materials to improve energy density and reduce costs. With this funding, Forge Nano aims to expand its battery coating operations and develop lithium-ion battery prototypes at its Colorado facility. This collaboration is expected to boost the range and fast-charging capabilities of GM’s future EV batteries.

About Forge Nano:

Forge Nano is a materials science company specializing in advanced surface engineering technology, particularly Atomic Layer Deposition (ALD). Its proprietary technology, "Atomic Armor," applies ultra-thin coatings at the atomic scale to improve the performance and durability of materials, particularly for energy storage applications like electric vehicle (EV) batteries. Forge Nano's coatings help enhance battery life, efficiency, and fast-charging capabilities by preventing corrosion and boosting cathode material performance.

Founded in Colorado, Forge Nano has attracted significant investment from major corporations, including General Motors, Volkswagen, LG, and others. The company's solutions extend beyond the automotive industry, targeting sectors such as electronics, aerospace, and defense. With ongoing innovation, Forge Nano aims to revolutionize how materials perform in critical technologies such as semiconductors and batteries.

Sources: 

www.forgenano.com

Forge Nano Receives $10M Investment from GM Ventures to Pursue GM Battery Material Enhancements for Future Electric Vehicles - Forge Nano

Forge Battery Begins Shipping High-Energy 300 Wh/kg Lithium-Ion Cells Made in The USA

Forge Battery, a subsidiary of Forge Nano, has initiated the shipment of its advanced 21700 cylindrical lithium-ion battery cells, branded as “Gen. 1.1 Supercell,” to customers and potential partners. The cells, which boast a specific energy of 300 Wh/kg, have passed rigorous safety certifications (UN 38.3 and UL 1642), allowing for safe transportation. The company plans to deliver thousands of cells throughout 2024, fulfilling existing customer commitments and generating interest from new markets. These cells are designed with over 20% silicon in the anode and use NMC 811 cathodes, outperforming U.S. Advanced Battery Consortium (USABC) energy density targets and reducing costs by 20% per kWh.

The Supercells incorporate Forge Nano’s proprietary Atomic Armor™ coating technology, enhancing the durability and performance of the cells by preventing unwanted chemical reactions. With 90% of the materials sourced from U.S. suppliers, Forge Battery is set to become a key player in the domestic battery market, aiming for full-scale production at its upcoming North Carolina Gigafactory in 2026. These cells are targeted at high-performance applications, including electric trucks, aerospace, and defence, with the potential to outcompete current Tier 1 global suppliers.

Source:

Forge Battery Begins Bulk Customer Shipments of 300 Wh/kg Lithium-Ion Battery Cells - Forge Nano

Forge Nano Unveils Plans for U.S.-Based Lithium-Ion Battery Gigafactory in North Carolina, Set to Launch in 2026

Forge Nano, Inc. has announced its venture into lithium-ion battery manufacturing with the creation of Forge Battery. The company plans to establish a Gigafactory in Raleigh, North Carolina, targeting defense, aerospace, and specialty electric vehicle markets. With an initial investment of over $165M, the facility, operational by 2026, will produce batteries utilizing Forge Nano’s Atomic Armor surface technology, enhancing energy density, safety, and lifespan. 

This technology is expected to surpass existing lithium-ion cells in performance. The North Carolina facility, benefiting from state incentives and a Job Development Investment Grant, promises significant economic benefits, including hundreds of high-paying jobs and substantial tax revenue to support local communities. The groundbreaking event is scheduled for the first half of 2024.

• Forge Nano has raised $81.54M over 10 rounds.
• Forge Nano's latest funding round was a Series C for on May 30, 2023.

Source:

Forge Nano to Launch U.S Battery Manufacturing Business; North Carolina Gigafactory Planned for 2026 - Forge Nano

Forge Nano Stock Price, Funding, Valuation, Revenue & Financial Statements (cbinsights.com)

ALD Adaptation Promises Advances in Solid-State Battery Development

Researchers at the Argonne National Laboratory have ingeniously applied a ALD, to improve solid-state battery technology. They adapted ALD, commonly used for applying thin films in chip manufacturing, to enhance argyrodite electrolytes—a sulfur-based compound known for high ionic conductivity, which is crucial for fast-charging batteries. The ALD process involves a chemical reaction on the material's surface to create a thin protective layer, addressing the reactivity challenges of argyrodites. Unlike typical post-pellet coating, this approach uniformly applies alumina coatings to electrolyte powders before pellet formation, preserving the material's structure. This results in less air-sensitive powders, facilitating easier production and leading to batteries with better performance, as demonstrated in cell tests. The method unexpectedly also doubles the ionic conductivity and mitigates issues like dendrite formation, significantly extending the battery's life and safety, marking a promising development for solid-state battery production.

Sources:

Adapting Semiconductor Techniques For Enhanced Battery Development (electronicsforu.com)

Zachary D. Hood et al, Multifunctional Coatings on Sulfide‐Based Solid Electrolyte Powders with Enhanced Processability, Stability, and Performance for Solid‐State Batteries, Advanced Materials (2023). DOI: 10.1002/adma.202300673

China Tightens Grip on Vital Graphite Exports Amid Global EV Surge: Implications for U.S. Battery Industry and Beyond

From December 1, China will mandate export permits for certain graphite products to safeguard national security amidst increasing international scrutiny over its manufacturing dominance. China supplies 67% of global natural graphite and refines over 90% used in EV battery anodes. This move coincides with foreign governments pressuring Chinese firms on their industrial practices. The U.S. and European Union are implementing measures against Chinese products and technologies. New Western investments aim to counter China's graphite dominance, but success remains uncertain.

According to the USGS, in 2022, the United States did not produce any natural graphite. Instead, 95 U.S. companies consumed 72,000 tons of it, valued at $140 million. These companies were mainly located in the Great Lakes and Northeast regions. Natural graphite was used in batteries, brake linings, lubricants, steelmaking, and other applications. The U.S. imported an estimated 82,000 tons of graphite in 2022, with 77% being flake and high-purity graphite. Due to the rising electric-vehicle market, graphite consumption is expected to grow. Since 2018, the global battery market for graphite has surged by 250%. The U.S. has four operational lithium-ion battery plants and 21 more in development. These plants, when fully operational, will need about 1.2 million tons of spherical purified graphite annually, with 40%-60% sourced from synthetic graphite.

Source: USGS

U.S. graphite imports saw a decline in 2019 and 2020 but rose by 55% in 2022. This increase is attributed to the demand from the lithium-ion battery industry. China dominated the graphite production in 2022, accounting for 65% of the global output. North America's graphite production was just 1.2% of the global supply. Projects to explore and produce graphite are ongoing worldwide. The geopolitical conflict in Ukraine has impacted graphite production and trade relations, affecting the global graphite market.

Europe heavily relies on graphite imports, primarily from China, but aims to reduce this dependency by advancing local mining projects. The EU has categorized graphite as a critical raw material due to its importance in the EV battery sector. Notably, mining initiatives in Sweden, such as Woxna Graphite Mine, and Norway's Skaland Graphite operation are underway to bolster local supply chains. With the rise of European battery gigafactories, securing a stable graphite supply has become imperative.

Why is graphite important?

Graphite is a crucial component in electric vehicle (EV) batteries, specifically in the lithium-ion batteries that power most EVs. Here's how graphite is used:

Anode Material: In a lithium-ion battery, there are three primary parts: the cathode (positive electrode), the anode (negative electrode), and the electrolyte. Graphite is used as the primary material for the anode. When the battery is being charged, lithium ions move from the cathode through the electrolyte and get stored between the layers of graphite in the anode.

Conductivity: Graphite is a good conductor of electricity. This property is essential for efficiently moving electrons in and out of the anode during the charging and discharging cycles of the battery.

Stability: Graphite has a layered, planar structure. This allows lithium ions to easily slip between these layers, a process called intercalation. This structure provides a stable housing for lithium ions, ensuring the battery's longevity and safety.

Volume Expansion: One of the challenges with lithium-ion batteries is that materials can expand and contract significantly as they absorb and release lithium ions. Graphite's structure can accommodate this volume change, helping to maintain the integrity of the electrode.

Natural vs. Synthetic Graphite: There are two main types of graphite used in EV batteries: natural flake graphite and synthetic graphite. Both types can be processed to achieve the desired properties for battery anodes. While natural graphite is mined, synthetic graphite is produced from petroleum coke.

The increasing demand for EVs has led to a surge in the need for graphite. As a result, the sourcing, processing, and supply chain for graphite have become critical considerations for the battery and EV industries.

Sources:

China, top graphite producer, to curb exports of key battery material (cnbc.com)

Graphite (Natural) (usgs.gov)

Forge Nano and KULR Partner for Cutting-Edge Battery Safety & Performance

In a significant move to enhance battery safety and efficiency, KULR Technology Group, a key player in sustainable energy management, has formed a strategic partnership with Forge Nano, renowned for its precision nanocoating technology. This alliance, estimated to be worth between $3.5 million to $5 million, will amalgamate KULR ONE Design Solutions - which offers advanced battery cell screening - with Forge Nano’s Atomic Layer Deposition (ALD) coating technique.

The collaboration begins with an assessment of Forge Nano’s elite battery cells intended for space and the US Department of Defense (DoD). KULR's innovative automated cell screening will be instrumental in gauging various battery cell parameters, ensuring they adhere to stringent NASA flight specifications.

In light of the recent announcement by the U.S. Department of Energy about a second tranche of $3 billion funding for battery production and recycling, this partnership positions itself as a catalyst in setting new benchmarks in battery safety and performance. 

Forge Nano, after securing $50 million earlier this year, has been aggressively investing in augmenting its battery production capacities. While KULR, with its expansive market presence in diverse sectors, sees this collaboration as a strategic alignment towards advancing the future of energy storage.

Source: Forge Nano and KULR Form a Strategic Partnership for Enhanced Battery Safety and Performance - Forge Nano

6K Energy Partners with Forge Nano to Revolutionize Battery Material Production

6K Energy, a trailblazer in sustainable battery material production, has joined forces with Forge Nano to introduce cutting-edge Atomic Layer Deposition (ALD) technology for commercial-scale production of NMC 811 cathodes. This collaboration aims to transform the battery industry by enhancing performance, efficiency, and cost-effectiveness.

Forge Nano, known for its precision nano-coating technology, and 6K Energy are set to redefine battery material production. By integrating Forge Nano's proprietary Atomic Armor™ surface technology into 6K Energy's process, the partnership promises unparalleled advancements.

Atomic Armor employs ALD coatings with unprecedented precision and speed. This method enhances battery materials, resulting in superior capacity, safety, charging rates, and cost-efficiency. Combining Forge Nano's Atomic Armor with 6K Energy's innovative UniMelt® materials production process is expected to yield high-performance and cost-effective battery materials.

Dr. Richard Holman, Senior VP of Battery Products at 6K Energy, emphasizes the impact of the collaboration, stating, "Leveraging Forge Nano's Atomic Armor platform provides us with a coating technology that meets the stringent specifications of our lithium-ion battery materials."

6K Energy's mission to produce domestically sourced battery materials for electric vehicles and renewable energy is greatly amplified by this collaboration. As the demand for advanced battery technologies grows, strategic partnerships like this one are poised to drive sustainable and high-performance solutions.

About 6K:

6K is a sustainability-driven company offering innovative solutions across industries. Their UniMelt® microwave plasma production system transforms materials into groundbreaking products. The company's 6,000-degree philosophy signifies both the operational temperature of UniMelt and the sun's surface temperature. 6K Energy, a division focused on domestically sourced battery materials, accelerates the transition to electric vehicles and renewable energy.

For more information, visit www.6Kinc.com.

6K Energy to Implement Forge Nano Equipment for Commercial Production of NMC 811 - Forge Nano

TRION Battery and Forge Nano Partner to Advance Lithium-Ion Battery ALD Tech

TRION Battery Technologies and Forge Nano have teamed up to revolutionize lithium-ion battery performance. This strategic partnership combines Forge Nano's Atomic Layer Deposition (ALD) coating technology with TRION's innovative SX-silicon materials to enhance batteries for aerospace, defense, and other high-demand markets.

TRION Battery Technologies and Forge Nano have signed a Memorandum of Understanding (MoU) to jointly develop lithium-ion battery solutions. This collaboration marks the beginning of a journey toward improved battery performance.

Forge Nano's ALD material coatings have shown significant improvements on various battery electrode materials. The partnership aims to achieve similar breakthroughs by combining these coatings with TRION's SX-silicon materials. TRION's SX-silicon has successfully overcome challenges associated with silicon use in batteries, achieving impressive milestones.

This partnership caters to demanding markets like defense, aerospace, and electric mobility. As batteries become vital in these sectors, the collaboration promises to showcase the strengths of both technologies.

The partnership accelerates TRION's SX-silicon commercialization strategy, reinforcing its value proposition to cell manufacturers. Forge Nano sees the partnership as aligning with their target markets and aims to establish a strong US supply chain.

The MoU outlines joint testing of ALD coatings on TRION's SX-silicon. The partnership aims to extend battery life, improve energy density, and enhance overall safety and efficiency in lithium-ion batteries.

TRION Battery and Forge Nano's partnership is set to reshape lithium-ion battery technology. By combining their expertise and materials, they're on a path to enhance battery capabilities for critical industries. This collaboration demonstrates the potential of synergy in driving technological advancement

TRION Battery Technologies and Forge Nano are poised to revolutionize lithium-ion battery safety and performance through their strategic collaboration. Integrating Forge Nano's advanced Atomic Layer Deposition (ALD) technology, known as Atomic Armor®, with TRION's innovative SX-silicon materials, the partnership aims to enhance battery capabilities for aerospace, defense, and beyond. By creating protective ALD coatings on electrode surfaces, they prevent degradation, improve heat dissipation, and mitigate reactivity during thermal runaway. This innovative approach not only promises higher performance but also addresses critical safety concerns, solidifying their position as pioneers in the realm of advanced battery technology.

ATOMIC LAYER DEPOSITION FOR AUTOMOTIVE BATTERIES - Forge Nano.

Atomic Layer Deposition: Revolutionizing Battery Performance with Nanotech Precision

The ALD Process Offers Promising Solutions for Extended Battery Life and Enhanced Stability

In recent years, the demand for high-performance batteries has soared due to the growth of electric vehicles, renewable energy systems, and portable electronic devices. To meet these demands, researchers have turned to atomic layer deposition (ALD), a nanotechnology-based process that enables precise control of thin film materials at the atomic scale. ALD has shown great promise in boosting battery life and improving stability.

One of the major challenges in battery development is maintaining the structural integrity of electrodes during charge and discharge cycles. ALD addresses this by creating protective coatings on electrode materials, such as alumina or titania. These coatings prevent unwanted reactions and stabilize the solid electrolyte interphase (SEI), improving cycling stability.

ALD also improves electrolyte performance by creating hybrid organic-inorganic electrolytes with enhanced ionic conductivity and thermal stability. These electrolytes offer potential for safer and more efficient batteries, especially in high-temperature applications. Additionally, ALD enables the fabrication of advanced electrode materials with tailored nanostructures, boosting electrochemical performance.

Full article: Atomic Layer Deposition: The Nanotech Boost for Battery Life - EnergyPortal.eu

US company Forge Nano raised US$50 M with Korea's Hanwha Corporate Venture Capital for Battery Pilot Line

US company Forge Nano has successfully raised over $50 million in its recent funding round, with Korea's Hanwha Corporate Venture Capital leading the investment. Other participants included Orion Infrastructure Capital, Catalus Capital, Ascent Funds, and existing investors. This funding brings Forge Nano's total capital raised to date to over $95 million.

The funds will enable Forge Nano to seize the growing opportunities in commercial-scale nanotechnology for battery materials and establish a battery production line capable of meeting the demand for premium batteries. The company plans to commence construction of a pilot battery production line in the second quarter of 2023, catering to various industries such as aerospace, consumer electronics, and defense.

Forge Nano's proprietary technology, known as Atomic Armor, is widely employed in battery applications for vehicles, aerospace, consumer electronics, defense, and other high-end Li-ion users. With this new funding, Forge Nano aims to further develop and scale its Atomic Armor technology within the lithium-ion market, enabling the company to offer finished battery solutions at scale.

The funding will also enhance Forge Nano's capabilities in applying Atomic Armor across different industries. By expanding its manufacturing footprint and allocating more resources to customer support, the company expects to increase its production capacity fivefold while improving tool production efficiency through the integration of digital management infrastructure.

Forge Nano has recently formed strategic partnerships with prominent U.S. material producers and battery off-takers, highlighting the capabilities of its proprietary nanocoating technology, Atomic Armor. These partnerships aim to develop next-generation batteries and strengthen the U.S. domestic battery supply chain. For instance, Forge Nano's collaboration with Anovion, a U.S.-based battery material producer, combines Forge Nano's surface engineering expertise with Anovion's synthetic graphite to create industry-leading lithium-ion batteries.

The company foresees substantial revenue growth in 2023 and expects to double its revenue once again through increasing market adoption. Forge Nano's Atomic Armor technology empowers manufacturers to engineer materials at the atomic level, optimizing battery characteristics such as range, safety, and cycle life. With a team of experienced scientists and a broad portfolio of commercial partners, Forge Nano offers tailored solutions across the entire spectrum, from small-scale research and development to large-scale, high-volume production.

Source:

Forge Nano Raises US $50M to Build Out Battery Production Line to Meet Growing Demand for Premium Batteries - Forge Nano

Forge Nano Partners with Aleon Renewable Metals for Battery Recycling and Supply of ALD Materials for EV Batteries

DENVER , May 2, 2023 /PRNewswire/ -- Forge Nano, a global leader in surface engineering and precision nano-coating technology, and Aleon Renewable Metals (ARM), an integrated lithium-ion battery recycler, announced a partnership today for battery recycling and supply of battery materials. Aleon Renewable Metals will recycle Forge Nano's battery scrap at its industry-leading battery recycling facilities in Texas and Oklahoma utilizing Forge Nano's technology to manufacture cathode active materials (CAM) from the battery grade materials produced by ARM. These facilities aim to make battery recycling easier and more cost effective while outputting leading CAMs made in the U.S. using Forge Nano's proprietary Atomic Layer Deposition (ALD) coating technology, Atomic Armor™. Batteries made with Atomic Armor are optimized to be longer-lasting and safer than current batteries on the market. ARM's facility is expected to annually produce battery grade materials equivalent to 35 GWh of renewable power.

Approximately three billion batteries are thrown away every year in America alone, posing environmental and economical threats far beyond the lifetime of the battery itself. Until now, few companies have addressed the challenges of recycling lithium-ion battery materials. Together, Forge Nano and Aleon are bringing over four decades of combined experience aiming to make E-waste a thing of the past with a 100% renewable energy process.

"In partnership with Aleon Renewable Metals, our technology will be used to provide sustainable and significant cost and performance advantages over competing recyclers making CAMs," said James Trevey , CTO, Forge Nano. "With the cost and performance benefits enabled by Atomic Armor, implementation of this U.S.-born nano-coating technology into the battery-recycling loop embodies the leapfrog improvement in technological advancement everyone has been waiting for in the lithium-ion battery industry."

"We are dedicated to driving sustainability and innovation. Aleon Renewable Metals leverages our proprietary recycling technologies to support the global transition to circular supply chains and cleaner energy. Our high-purity, cost-competitive battery grade materials are positioned to meet the growing domestic demands of the EV market for metal sulfates and lithium compounds used in high-performance cathodes," said Tarun Bhatt , CEO of Aleon Renewable Metals. "With our experience in metal recovery and commitment to sustainable solutions, we are excited to partner with Forge Nano to develop downstream cathode active materials. Together, we will address the projected lithium, nickel, and cobalt supply/demand deficits to create a more attractive environment for sustainable energy production."

As active members of NAATBatt and the MPSC , both companies have demonstrated their dedication to a sustainable battery ecosystem, and their commitment to making a difference in the battery waste problem. This exciting partnership will bring together two world-renowned battery powerhouses in the hopes of taking battery recycling technology to the next level.

"Particle coatings in the field of battery technology are an enabler to excel in the marketplace, which Forge Nano is doing as the global leader in ALD methods to achieve the essential coating characteristics," said Bob Galyen , energy storage technology expert and chairman of Galyen Energy. "The U.S. battery supply chain depends on this kind of innovation to compete on the world stage."

Ascent Funds Invests in Forge Nano Atomic Armor for Lithium-Ion Batteries & Hydrogen Fuel Cells

September 13, 2022; Miami, USA: Ascent Funds (“Ascent”), an energy-tech venture company today announced it has invested in Forge Nano Inc (“Forge Nano”), inventor of nanocoating technology Atomic Armor, which coats a protective atomic layer on a wide range of materials, powders and products to deliver greater performance for a lower cost. Forge Nano is preparing to build a US$120 million 500MWh Atomic Armor battery facility in Denver, Colorado which will deliver some of the most efficient and longest lasting batteries in the world.

Batteries that have Atomic Armor; last 100% longer, charge 300% faster

Forge Nano is the global leader in scalable atomic layer deposition (“ALD”), a unique coating technology that produces a protective atomic layer on a range of materials, powders, and products providing greater protection, performance, durability and safety.

Invented in the 1960s, ALD is mainly used in the semiconductor and OLED industries with the technology commonly found in many mobile phone components. Since 2011, Forge Nano has developed a proprietary ALD process that allows for four times faster coating speeds than any other semiconductor ALD tool provider and enables scale for use on powders and larger surface area objects, such as; lithium-ion batteries, hydrogen fuel cells, pharmaceuticals and vaccines, consumer, sporting and apparel products. Forge Nano calls their ALD coating Atomic Armor.

Atomic Armor works especially well for battery materials, where it stabilizes the surfaces at the atomic level. These coatings prevent excessive wear and damage to the batteries by preventing unwanted reactions among the battery’s internal components. Batteries that have Atomic Armor last 100% longer, charge 300% faster, and dissipate heat more effectively.

Over the past decade, Forge Nano has emerged as a market leader in large-scale ALD. In 2021, Forge Nano announced the world’s first ALD enabled battery for space, with the launching of a high energy lithium-ion battery into orbit aboard the SpaceX Transporter-2 rideshare mission. The Li-ion batteries, featuring Forge Nano Particle ALD technology and Enersys Zero Volt Technology were integrated into spire Global, Inc’s LEMUR-2 satellite.

Atomic Armor can improve performance in hydrogen fuel cells, electrolyzers and storage

Since 2019, Forge Nano has collaborated with the U.S Department of Energy’s National Renewable Energy Laboratory, University of Connecticut, Colorado School of Mines and Fraunhofer Institute of Solar Energy Systems in Germany to accelerate the development of more efficient component parts for hydrogen fuel cells, electrolyzers and hydrogen storage technology. In the hydrogen value chain, Forge Nano’s Atomic Armor can transition fuel cells away from low-scale, costly electrode fabrications while increasing durability and limiting the use of platinum group metals. This reduces both the cost of the fuel cell as well as the technology’s dependence on expensive metals.

Mr David Wu, President of Ascent Funds said, “At Ascent, we look for transformational technology that can have an immediate and profound impact on the energy transition, especially in the hydrogen ecosystem. With over a decade’s experience in enhancing lithium-ion batteries and other materials, Forge Nano is the only commercially large-scale ALD player that can offer a real step-change in productivity, performance and cost for hydrogen companies. For example, instead of using expensive platinum or titanium catalysts, fuel cells could use low cost metal catalysts coated with atomic armor. Until now, atomic armor for hydrogen technology was a theoretical ambition because it couldn’t be scaled – today, atomic armor is a reality’.

Mr. Paul Lichty, CEO of Forge Nano, said: “We are excited to have Ascent join us as investors and advisors. They have a strong track record in identifying game changing technologies and helping those companies to scale and commercialize. In addition, Ascent’s knowledge and experience across the global hydrogen industry will be paramount as our technology becomes an accelerant in the energy transition, particularly for mobility, be it BEV or FCEV.”

Ascent joins existing shareholders Volkswagens, LG Chem, Air-Liquide, Mitsui Kinzoku, Sumitomo and SCG from Thailand.

Materion to develop advanced chemicals for EV batteries, semiconductor chips at new facility

Materion Corporation (NYSE: MTRN), a world leader in high-performing advanced materials, announced today that it has established a new facility in Milwaukee, Wisconsin to accelerate the growth of advanced chemical solutions for the semiconductor and electric vehicle (EV) battery markets.

The new 150,000 square foot facility expands the company’s capacity to produce Atomic Layer Deposition (ALD) materials for the most sophisticated semiconductor chips and provide advanced chemicals for the development of next-generation battery technology for EV’s. Production capabilities are expected to ramp up during the first half of next year.

“This expansion is in direct response to the confidence that our customers have in Materion as a critical partner in the development of game-changing technologies to advance growth aligned with these exciting megatrends,” President and CEO Jugal Vijayvargiya said. “We are proud of the role that we will play in the development of the most technically advanced semiconductor chips for a wide variety of applications as well as next-generation batteries that will support the broader adoption of electric vehicles globally.”

Building on Materion’s existing portfolio of electronic materials and premium thin film target solutions, the expansion of its ALD capabilities will significantly enhance the company’s position as a leading global supplier to the high-growth semiconductor industry. The move follows the company’s successful 2021 acquisition of the HCS-Electronic Materials business, which added tantalum- and niobium- based solutions to Materion’s portfolio of precious and non-precious metal targets, extending the company’s global reach and expanding its position with leading semiconductor chip manufacturers.

On the EV front, Materion is working with a number of leading battery manufacturers on the development of inorganic chemicals to be used in their next-generation battery solutions focused on enabling longer range, faster-charging and enhanced safety. Following a multi-year R&D partnership, one specific customer is funding $6 million to establish a prototype line in the new Milwaukee facility. Materion’s relationships with next-generation battery customers are expected to further strengthen the company’s already strong position as a critical supplier to the automotive market, as today the company develops advanced materials for use in a wide variety of applications that include battery and electric connectors and lidar optics.

About Materion

Materion Corporation is headquartered in Mayfield Heights, Ohio. Materion, through its wholly owned subsidiaries, supplies highly engineered advanced enabling materials to global markets. Products include precious and non-precious specialty metals, inorganic chemicals and powders, specialty coatings, specialty engineered beryllium alloys, beryllium and beryllium composites, and engineered clad and plated metal systems.

Source: Materion Corporation - Materion Establishes New Facility to Accelerate Growth in the Semiconductor and Electric Vehicle Markets

Dutch deep tech start-up Delft IMP secures €10 million series A funding to scale up technology that radically extends battery life

Sandwater, a Nordic venture capitalist and Invest-NL have agreed to a €10 million investment in Delft IMP. This allows Delft IMP to accelerate their nanocoating process to industrial scale enabling more durable batteries and other sustainable applications. The investors in this Series A are Sandwater and Invest-NL. Sandwater has a broad portfolio of investments aiming to enable progress together with its founders. Invest-NL is the government owned impact investor supporting innovation and sustainability in the Netherlands. 

Delft IMP has unique expertise in developing ultra-thin coatings on powders and has the proprietary technology to produce these materials at scale. The ultra-thin nanocoatings protect, for example battery powder from the harsh surroundings and thus enhances the life time of the battery. The Delft IMP application technology enables them to control the process to optimize the film thickness and reduce the use of scarce raw materials. 

Ruud van Ommen

Founder & Professor in Chemical Engineering at TU Delft

Jacob Moulijn

Founder & Emeritus Professor in Catalysis Engineering at TU Delft

The real benefit of the Delft IMP technology comes from the elegant way they are able to scale up the atomic layer deposition (ALD) based coating process to industrial scale. This makes it possible to deliver this benefit cost effective to a wide range of battery applications, supporting the electrification of mobility. Coating the battery powders, provides the flexibility to encounter this benefit in current and also future generations. Delft IMP is not your next battery company, but instead they work together with leading battery companies to extend the lifetime of batteries and reduce the consumption of scarce minerals. This facilitates the sustainable use of raw materials, and will also bring radical performance improvements to other technologies such as electrolysers and fuel cells. 

“We are solving the big problems in the world, by going very small: We are applying ultra-thin coatings on powder material and enable production at scale with a unique technology originating from Delft University of Technology.” said Dr. Roderik Colen, CEO of Delft IMP. 

Torkel Engeness (Sandwater) “We at Sandwater are in the market for the radical solutions of tomorrow. Sandwater believes that active ownership enables progress and is looking forward to sharing the journey together with Invest NL and Delft IMP”.

Forge Nano and Mineral Commodities Enter Into MOU to Produce ALD-Coated Natural Graphite Anode Powders

DENVER, Aug. 19, 2021 [LINK] - Mineral Commodities Ltd., Perth l, WA, Australia, and Forge Nano Inc., Colorado, USA have signed a memorandum of understanding ("MOU") for the use of Forge Nano's proprietary Atomic Layer Deposition coating technology ("ALD"). Forge Nano's surface engineering platform technology will be used to apply atomic level coatings to Mineral Commodities' natural graphite materials.

Dr. Surinder Ghag, MRC's Chief Technology Officer, explains: "By combining our high-quality natural graphite with Forge Nano's ALD coating technology, we can produce a high-performing, cost-competitive graphite anode powder for lithium-ion batteries. We're very excited about this long-term partnership as we target sustainable European anode production in the coming years. This collaboration enables the Company to continue building its technical expertise as it moves towards demonstrating a downstream process for graphite spheronization, purification and coating."

Paul Lichty, Forge Nano's Chief Executive Officer, adds: "We are excited to be fully supporting Mineral Commodities as a key technology partner in their path towards large-scale anode powder production. Our high-throughput ALD coating technology will enable them to compete with established anode producers globally. The collaboration adds to our growing set of partnerships in the graphite anode space, a testament to the value of our technology."

Why does the ALD coating process work so well for graphite anode powders?

ALD coatings on graphite anode powder stabilize the surface defects. This ALD stabilization results in better anode powders with higher discharge capacities, longer life, and improved rate performance. Batteries using ALD-stabilized graphite show increased cycle life, reduced capacity fade, increased conductivity, and greater stability under a variety of conditions such as high voltage, fast charge, or high/low temperature storage and operation. Additionally, Atomic Layer Deposition (ALD) is a potential replacement for carbon coatings on natural graphite powders, a process that few companies have the know-how for.

BASF and Umicore have entered a non-exclusive patent cross-license agreement for battery cathode active materials and their precursors

BASF and Umicore have entered into a non-exclusive patent cross-license agreement covering a broad range of cathode active materials (CAM) and their precursors (PCAM), including chemistries such as nickel cobalt manganese (NCM), nickel cobalt aluminum (NCA), nickel cobalt manganese aluminum (NCMA) and lithium rich, high manganese high energy NCM (HE NCM).

CAMs are critical for the performance, safety and cost of lithium-ion batteries used in modern electromobility and other applications. The interplay between PCAM and CAM and the development of these materials are crucial to maximize battery cell performance. For many years, BASF and Umicore have been investing intensively in product innovation for low, medium and high nickel PCAM and CAM resulting in each company owning sizeable and largely complementary patent portfolios.

BASF Research on high-performance battery materials at BASF’s laboratory in Ludwigshafen, Germany (above). Umicore 3D open battery cell (below).

Building on each other’s strong product technology expertise to support the technological needs of their customers, BASF and Umicore have entered into a landmark patent agreement allowing both partners to combine a wider range of IP-protected technologies related to features such as chemical composition, powder morphology and chemical stability. The agreement increases both parties’ ability to customize their materials to meet the increasingly diversified and complex customer requirements at the battery cell and application level. Furthermore, through this agreement both parties can increase even more their product development speed demonstrating their commitment to addressing the main challenges e-mobility is facing, such as energy density, safety and cost while enhancing transparency and reducing IP-risks for battery cell manufacturers and their customers.

The agreement covers more than 100 patent families filed in Europe, US, China, Korea and Japan. Both parties retain the right to enforce their own IP-rights against third parties in the future.

“This agreement with Umicore enables even faster, more sustainable and innovative battery materials development to serve our customers including battery cell manufacturers and automotive,” said Dr. Peter Schuhmacher, President of BASF Catalysts. “The continuous development of battery materials will accelerate the transformation towards full electrification and thus support the world’s efforts to fight climate change.”

Marc Grynberg, CEO of Umicore, commented: “This agreement with BASF is an important step in promoting cathode material innovation. It strengthens our technology positioning and further increases our ability to develop bespoke solutions which meet the most stringent performance and quality standards of our battery and automotive customers.”

Canada's Gratomic Enters EV Battery Supply Chain With Forge Nano and ALD

TORONTO, ON / ACCESSWIRE / Wednesday, March 31, 2021 / Gratomic Inc. ("GRAT", "Gratomic" or the "Company") (TSXV:GRAT)(OTCQX:CBULF)(FRANKFURT:CB82) is pleased to announce its plans to build a pilot facility (the "Facility") to internally process up to 1,000 tons of SG16 battery grade anode materials for the booming Electronic Vehicle ("EV") battery market in the second half of 2021. This initial pilot facility, if successful (as demonstrated by internal testing), is expected to be followed by the construction of a demonstration facility, which will process up to approximately 2,000 tons per annum beginning in 2022 and up to 20,000 tons per annum once the demonstration facility is converted into a full final production phase. The facility will be located at the Company's owned warehouse located at the Port of Luderitz Bay. While Gratomic completes the development of the pilot facility graphitic material will be shipped to Forge Nano, Inc. ("Forge Nano") for Atomic Layer Deposition ("ALD") coating in preparation for use as a battery anode material. This processing facility will enable the Company to take our raw graphite material to the final stages required for use in a battery anode application.

Forge Nano's ALD coating technology for use in lithium-ion battery anode applications, could result in significant gains in performance to Gratomic's SG16 battery graphite compounds, as per our press release dated October28. The Company has therefore entered into a cooperative agreement with Forge Nano, a leading expert in the field of battery materials (www.forgenano.com), to not only undertake the ALD coating process but also to assist in the planning and development of GRAT's aforementioned processing facility. Battery anode materials generally consists of three stages of processing: micronization, spheronization and coating. Forge Nano specializes in the final coating stage with their patented ALD coating technology. This facility will work in tandem with the Company's Aukam vein graphite project, which is now in its commissioning phase (See Company's press release dated March 29).

Procurement of the equipment system capable of applying ALD coatings for use in the Facility will be released by Forge Nano upon the successful completion of various performance and cost milestones (See "Scope of Collaboration" below).

Gratomic's Ludertiz Bay property covers 6,564 square meters and contains three buildings including a large warehouse, a double garage with six storerooms/workshops and a single garage with two offices and a store-room. The Company intends to use the warehouse for the ALD processing and packaging of its graphite. The property provides Gratomic with waterfront access to the Port of Luderitz and to container facilities, enabling direct delivery to ports in Europe, Asia and North America.

Furtehr details: LINK

Woxna AB in Sweden & Forge Nano USA to evaluate ALD coated graphite anode material for Lithium batteries

Sweden is steaming ahead in the Li-battery supply chain with Gigafab activities in North Sweden by Northvolt and traditionally have a strong Automotive sector led by Volvo Cars, Volvo Trucks, and Scania. Perhaps less known, there are also vast sources of graphite in Sweden and Woxna AB is one of the key mining companies for supplying graphite, which is a material needed for the anode in Li-battery production. So now the cool news - Woxna AB is going with ALD to coat the graphite anode material dug up at various places in Sweden! If the demonstrations are successful we are looking at a future demonstration plant at one of Woxnas graphite mining locations in Sweden - obviously, we will then move any plans of the ALD Sweden Conference to somewhere near that location and ask King Carl Gustav to join us in celebrating this historical milestone *fingers crossed*

ALD Company, Forge Nano, and Leading Edge Materials Corp., through its subsidiary Woxna Graphite AB are pleased to announce development work on the coating of graphite anode material from Woxna using Forge Nano's proprietary Atomic Layer Deposition technology (Press release: LINK).

Leading Edge Materials commenced graphite production at the Woxna Graphite project in July 2014. Woxna is strategically located in central Sweden, on the doorstep of a diverse range of European graphite consumers. Woxna is a fully permitted site, with an open pit mine, graphite processing facility and tailings storage dam already constructed. The site is currently permitted to feed 100,000 ton of graphitic rock per year, which allows for the production of approximately 10,000 tons of graphite concentrate (Source: Woxna Graphite AB, LINK)

From the press release: Compared with traditional coating technologies Forge Nano's ALD coatings offer added benefits such as the ability to control the thickness of the coating at the nanoscale, lower costs, reduced carbon footprint and equipment ready for commercial-scale production. As part of the agreement, Woxna will send samples of spherical purified graphite to Forge Nano for coating, performance testing, and evaluation against other previously carbon-coated Woxna spherical graphite materials. If successful, the agreement outlines a path to purchase equipment from Forge Nano with a capacity suited for deployment in a future demonstration plant at the Woxna graphite mine.

Filip Kozlowski, CEO of Leading Edge states "Coating is the last and most valuable step towards becoming a future active anode materials producer in Europe. Being offered the opportunity to collaborate with a market leader in this field like Forge Nano is a great step forward for the Woxna Graphite project. The advantages of Forge Nano's ALD coating for anode materials are well documented and with the support of some significant European investors in the battery value chain their technology could be the perfect solution to enable a sustainable source of high-performance active anode materials from Sweden."

Norwegian Morrow Batteries and Dutch startup Delft IMP have signed a JDA for ALD improved batteries

Morrow Batteries explores new technology with Dutch startup-company Morrow Batteries and Delft IMP have agreed to explore a joint collaboration in using ultra-thin coating technologies to produce lower cost and more sustainable batteries. Norway-based Morrow Batteries and Dutch-based startup Delft IMP have agreed to investigate the joint development of new improved batteries. The technology used is based on atomic layer deposition (ALD).

“We are applying ultra thin coatings on powder material and can produce these at scale with a unique technology originating from Delft University of Technology.” said Dr. Roderik Colen, CEO of Delft IMP. “It is a matter of time before breakthrough developments using ultra thin coatings become commercially available. The development of Morrow Industrialization Centre (MIC) provides us with a unique opportunity to demonstrate this at scale.”

Press release: LINK

Morrow Batteries AS: LINK

Morrow Industrialization Centre (MIC) will include a pilot manufacturing line and a R&D centre. We aim to start building MIC in 2022 and be operational in 2023.

Morrow Giga Factory will be a giga-scale battery cell manufacturing factory. We are currently evaluating alternative locations and expect to take a decision by the end of 2020. We aim to start cell manufacturing in our giga-scale battery cell factory by the end of 2024.

Delft IMP: LINK

Our spin-off @DelftIMP enters partnership with Morrow Batteries to jointly explore collaboration in using ultra-thin coating #batterytechnology to produce lower cost and more #sustainable #batteries in a Giga Factory.https://t.co/IES8g0aCwR pic.twitter.com/pcjLZbQkgz

— Ruud van Ommen (@JRvanOmmen) February 27, 2021