Hardened chemistry.
Stable interfaces.
Longer mission life.
Li-Ion Cells
No redesign.
No new chemistry.
Just hardened materials.
We don’t change the chemistry; we harden it. Atomic Armor™ stabilizes the reactive interfaces where performance traditionally fails. We convert unstable materials into controlled, durable systems ready for the field.
The result is superior voltage tolerance, extended mission life, and stabilized safety under extreme operating conditions.
Current State
The failure modes
limiting Li-Ion cells
-
01
INTERFACE INSTABILITY
Unprotected cathode and anode surfaces react aggressively with electrolytes, driving impedance growth, capacity loss and early cell failure.
-
02
CHEMICAL DEGRADATION
High-voltage operation accelerates parasitic reactions, gas generation and transition metal dissolution; compromising safety and lifetime.
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03
THERMAL & MECHANICAL STRESS
Repeated expansion, contraction and heat cycling fracture particle surfaces, exposing fresh reactive sites with every cycle.
-
04
SUPPLY CHAIN EXPOSURE
Critical battery materials and surface treatments rely on foreign controlled processes, creating geopolitical risk, delays and production fragility.
Engineering
battery reliability at
the atomic level
INTERPHASE STABILIZATION
RHEOLOGY CONTROL
HERMETIC SURFACE PROTECTION
DEFECT-FREE-NANO BARRIER LAYERS
Battery failure starts at the surface. Atomic Armor™ stabilizes active materials at the atomic level, protecting critical interfaces that determine performance, safety and yield.
Forge Nano’s platform enables durable, scalable battery materials that are engineered for repeatable production from lab to gigafactory.
From Particle to Pack:
Atomic Control for Every Cell
D35A™
The D35A is engineered for the unrelenting duty cycles of robotics and tactical hardware. It is the baseline for persistent operations.
- Capacity: 3.7 Ah
- Energy Density: 269 Wh/kg
- Cycle Life: 1,200+ (to 80% SOH)
- Operational Envelope: -30°C to 55°C
- Status: ACTIVE. Available for immediate integration
C35C™
Security begins at the atom. The C35C eliminates supply chain vulnerability. Every component is sourced and manufactured in the USA to meet the strictest Department of War mandates.
- Provenance: 100% US-sourced material
- Capacity: 3.6 Ah
- Energy Density: 260 Wh/kg
- Cycle Life: 450+ (to 80% SOH)
-
Max Charge/Discharge: ≥3C Continuous (C) / ≥2C Continuous (D)
- Status: RESERVE. Samples available now
C55C™
The C55C kills heat to maximize output. Utilizing a tab-less design in a lightweight aluminum housing, it delivers massive current for high-draw propulsion and edge-computing platforms without thermal throttling.
- Discharge Rate: ≥7C Continuous
- Capacity: 5.5 Ah
- Energy Density: 319 Wh/kg
- Charge Rate: ≥6C Continuous
- Status: DEVELOPMENT. Samples available Q2 2026
The Hardened Asset
Protection at the molecular level. Using our proprietary Atomic Armor™ , the F55A is shielded against degradation in the harshest conditions on or off-planet. It is the premier choice for aerospace and deep-cold operations.
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Core Tech: Atomic Armor™ ALD Coating Capacity: 5.5 Ah
-
Energy Density: ≥279 Wh/kg (at 0.1 C)
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Cycle Life: 1,200+ (to 80% SOH)
-
Max Charge/Discharge: ≥4C Continuous (C) / ≥3C Continuous (D)
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Low-Temp Ops: Discharge capable at -40°C
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Durability: Stainless steel housing
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Status: DEVELOPMENT Samples available Q2 2026
America’s
Gigafactory
RESHORING THE FUTURE OF HIGH-PERFORMANCE ENERGY
The global energy supply chain is fragile. Forge Nano is the solution. Located in Morrisville, North Carolina, our 3GWh Gigafactory is more than a manufacturing site—it is a transformational blueprint for U.S. energy security.We are delivering 100% domestic lithium-ion cell production at scale to ensure that the critical systems defending our borders and powering our infrastructure are never reliant on foreign adversaries.
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Capacity: 3GWh annual output
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Technology: Integrated Atomic Armor™ ALD coating lines
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Security: 100% U.S. based manufacturing and supply chain integrity
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Funding: Backed by a $100M U.S. Dept. of Energy grant
Uncompromising mission endurance
TOTAL STABILIZATION
Neutralize chemical decay at the molecular level. We lock the cathode structure in a permanent, non-reactive state to prevent capacity loss during high-stress missions.
KINETIC VELOCITY
Eliminate the charging bottleneck. Our surface-engineered interfaces allow for massive ion flux, enabling full combat-ready power in under 10 minutes without damaging the cell.
THERMAL HARDENING
Engineer safety into the chemistry, not just the pack. Atomic Armor™ creates a physical barrier that suppresses the exothermic triggers of thermal runaway, even in extreme heat.
GIGASCALE DEPLOYMENT
Move beyond the prototype. We utilize the world’s most advanced high-volume ALD architecture to deliver millions of hardened cells with total process consistency.
DOMESTIC CONTINUITY
Secure the tactical supply chain. From atomic coating to final assembly, our cells are produced in the United States to ensure mission-critical availability and TAA compliance.
Proof In Action
Testimonial
Forge Battery delivers the world’s most
durable high-energy cells. By integrating
Atomic Armor™ at the particle level, we
neutralize the chemical instability of highnickel
chemistries, unlocking performance
that Tier-1 incumbents cannot match.
James Trevey
Chief Technology Officer