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. ALDˣ stabilizes the interfaces where batteries fail — creating Atomic Armor™ at the material level. Unstable materials become controlled, durable systems ready for the field.
Higher voltage tolerance. Longer mission life. Built for extreme 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.
-
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.
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.
-
Capacity: 3GWh annual output
-
Technology: Integrated Atomic Armor™ ALD coating lines
-
Security: 100% U.S. based manufacturing and supply chain integrity
-
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
Insight
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