The primary challenge was rapidly scaling from R&D operations to a fully integrated, high-volume commercial battery manufacturing facility.

Detailed battery cell assembly drawings were still in development at project start, requiring early-stage definition to support scalable manufacturing design.

Budget discipline was critical as Forge Battery advanced the project while actively securing private capital and federal funding.

The selected facility was insufficient, and an additional structure needed to be designed with limited footprint for expansion.

Hatch leveraged its proven process-engineering toolset to define scalable production requirements, significantly reducing implementation risk during Forge Battery’s transition to mass manufacturing.

Hatch’s battery cell design and process experts served as subject matter experts advancing product-level assembly definitions using deep experience in R&D-to-commercialization transition.

Hatch worked closely with Forge Battery leadership to refine scope around critical priorities, maximizing deliverable value while supporting private investment and federal funding objectives within budget.

Hatch coordinated with the facility contractor to develop concepts that fit within available footprint and provided the necessary process space for battery cell production.

Enabled the successful transition of Forge Battery from R&D planning to gigafactory-scale production through a fully integrated design FEED package.

Delivered end-to-end production process and balance-of-plant integration to support a 2 GWh annual battery cell manufacturing facility.

Advanced product-level cell assembly definitions using deep commercialization expertise to de-risk large-scale implementation.

Hatch’s work directly supported Forge Battery’s successful pursuit of $100 million US Department of Energy (DOE) funding award.