Forge Battery Cell Production Facility
Advanced lithium-ion cell production with Atomic Armor™ Technology
Forge Battery
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Morrisville North Carolina, U.S.A
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2023-2024
USD$100 million grant from the US Department of Energy (DOE)
300 Wh/kg energy density due to Forge Nano’s Atomic Armor coating
3 GWh annual battery cell manufacturing facility
The facility will manufacture 21700 and 18650 lithium-ion battery cells using materials coated with Forge Nano’s Atomic Armor™ surface technology, which is designed to achieve an energy density of 300 Wh/kg with improved safety and an extended service life. Hatch supported Forge Battery in delivering the Design FEED Package (DFP) for the integration of a 3 GWh annual battery-cell manufacturing facility. This scope encompassed the full production process, as well as the integration and balance-of-plant (BOP) systems, facilities, and infrastructure. Hatch’s contribution was instrumental in enabling Forge Battery to secure a $100 million grant from the US Department of Energy (DOE).
Scope of work included:
- Production process – Design and integration of core manufacturing equipment and ancillary systems required for battery-cell production. The process is based on proven existing design scaled from Forge Nano’s operational facilities in Colorado.
- Balance of plant (facility/systems) – Design of all supporting infrastructure required for production operations, including power distribution. Non-process infrastructure (warehousing, offices, shipping/receiving, and building modification) to accommodate layout and operational requirements.
Challenges
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.
Solutions
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.
Highlights
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Enabled the successful transition of Forge Battery from R&D planning to gigafactory-scale production through a fully integrated design FEED package.
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Delivered end-to-end production process and balance-of-plant integration to support a 3 GWh annual battery cell manufacturing facility.
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Advanced product-level cell assembly definitions using deep commercialization expertise to de-risk large-scale implementation.
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Hatch’s work directly supported Forge Battery’s successful pursuit of $100 million US Department of Energy (DOE) funding award.
“Hatch’s disciplined FEL 2/3 process, beginning with process engineering and extending through facility requirements development and battery manufacturing equipment selection, provided exactly the clarity our cylindrical battery start-up required. Their disciplined approach and dependable guidance were invaluable during a complex and rapidly evolving effort.”
Project Numbers
- USD$100 million grant from the US Department of Energy (DOE)
- 300 Wh/kg energy density due to Forge Nano’s Atomic Armor coating
- 3 GWh annual battery cell manufacturing facility