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CRITICAL FACTORS FOR ENABLING NORTH AMERICAN LI-ION CELL MANUFACTURING
1. Electric Vehicles
Battery Tech USA 2022
March 2022
James Trevey Ph.D
Chief Technology Officer
Critical Factors For Enabling North American Li-ion Cell
Manufacturing
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End-to-End Material Solutions Provider
R&D Services
Toll-Coating (milligrams to kilotons)
Equipment Sales (Lab to Commercial-Scale)
*End Products*
• Founded in 2011
• 70 employees, 100% YoY growth past 3 years
• 40,000 ft2 facility near Denver, CO
• Scaled a nano-coating technology called ALD
• Typically engaged as innovation partner
• Technology demonstrated at giga-factory scale
• Developed a Li-ion battery formulation for 300Wh/kg
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ALD for Batteries
• ALD is applicable in many markets
• In Li-ion/Beyond Li-ion Batteries:
• Increases energy density
• Increases power density
• Increases cycle life
• Increases safety
• Decreases cost
ALD precision coatings deliver:
• Engineer the SEI enabling long-term
material integrity
• Cleans and protects surface, keeps
resistance low
• Reduces the occurrence of key
exothermic reactions
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High Energy
Density
Increased
Lifetime
Safer
Faster Charge Lower Cost Future Proof
(1) Independently validated by major auto manufacturer.
(2) Quantified by % reduction in exothermic energy from arc test.
(3) Projected for full-scale production based on detailed cost modeling.
~20%
increase in range
for same battery
size and chemistry
2-10x
increase in cycle
life(1)
50%
decrease in heat
generation(2)
Decrease rating to
EUCAR3(1)
10 minute
fast-charge without
sacrificing battery life
20%
lower cost per kWh(3)
Increased capacity and
voltage
Lower degradation rate
of time
More temperature
tolerant and lower fire
risk
Allows for higher
charge voltage
Replaces costly
processing steps
Keep up with battery
chemistry evolution
Improved
Li-metal and
solid-state
batteries
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ALD is a Customer Validated Technology Platform that Enhances Battery
Performance
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Forge Nano batteries serve key application relevant to the US market
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~20% increase
in range(1)
True 10-minute
fast charge(2)
Increased safety
20% lower cost per
kWh(3)
Electric
Vehicles
Extended cycle life
Heat tolerant
Grid
Storage
Heat tolerant fast
charge/discharge
Improved
calendar life
Longer battery life
Consumer Durables
In-space
demonstrated
Increased
temperature
performance
Aerospace
and Defense
(1) Projected performance in standard automobile.
(2) Using Forge Nano’s proprietary anode coating technology.
(3) Projected for full-scale production based on detailed cost modeling.
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“…this [is a] high-quality
technology is scalable and
able to be incorporated
cost-effectively into
everyday products.”
“…Forge Nano has developed
the technologies that enable
scale-up production and
commercialization
of this innovation for both
automotive
and non-automotive
applications.”
“ …We are acting as a partner
to Forge Nano and intend to
provide the team with
opportunities to carry
out industrial trials with its
innovative technology.”
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What do we have?
https://www.knowmade.com/press-release/news-power/e-mobility-new-eldorado-li-ion-batteries/
Consumer
visibility
• Strengths and weaknesses of US
• Strengths come from previous initiatives
• Didn’t go far enough down the chain
• Didn’t support demand (nobody did)
• Demand not enough for proper volume/pricing
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What was the result?
https://cicenergigune.com/en/blog/north-america-battle-electric-car-battery-gigafactories
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Now what?
• Assessment
• FCAB
• 100 Day Report
• National Blueprint for Lithium Batteries, 2021-2030
• Li-Bridge
• FOA-0002677 ($3B)
“Through the investments in the American
Jobs Plan, we can re-establish U.S.
leadership in electric vehicles and
batteries…these investments will ensure we
manufacture the next generation of vehicles
right here in America, lead the world in EV
and battery innovation…”
- President Joe Biden, May 18, 2021
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What worked for those who are leading?
• China
• Secured partnerships for raw materials
• Built-out processing facilities
• Co-location and vertical integration
• Domestic prioritization
• Recycling
• Good policy
• EU
• Get going on steel in the ground
• Tesla
• All of the above
• Innovation
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Moving Forward with Innovation
• Manufacturing is the US weakness
• Innovation is the US strength
US Innovation example data from https://www.drugcostfacts.org/how-does-us-maintain-its-leadership-innovation
Innovation
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Innovation in the US
• Two paths toward commercialization of innovation
• 2 years of giga-scale operation (lots of capital and risk) or
• Co-development between the big and the small
https://climatetechvc.substack.com/p/staying-current-with-the-battery?s=r
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Forge Nano the Innovation and Commercialization Partner
• Solving materials challenges
• Improved manufacturing (lower cost)
• Aqueous cathode processing
• Dry coating
• Reduced formation
• Reduced supply chain risk
• Improved performance
• Improved silicon performance
• Reduced moisture sensitivity
• Improved interfaces (lower resistance)
• Improvements upon state-of-the art
• Enabling/Improving upon next gen
https://www.build-electronic-circuits.com/current-voltage-resistance/
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“…this [is a] high-quality
technology is scalable and
able to be incorporated
cost-effectively into
everyday products.”
“…Forge Nano has developed
the technologies that enable
scale-up production and
commercialization
of this innovation for both
automotive
and non-automotive
applications.”
“ …We are acting as a partner
to Forge Nano and intend to
provide the team with
opportunities to carry
out industrial trials with its
innovative technology.”
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Thrust #1: Disrupting production of Graphite Anodes for LiB’s
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Forge Nano coatings Traditional Petroleum (Pitch) coatings
Process
overview
Single step, continuous
Low temp 150C operation
Multi-step batch process
>1200C post processing
Capital cost $10M >$20M 50% lower
CAPEX
Operating
cost
~$0.5 – 1 / kg ~$1 – 2 / kg Much lower
OPEX cost
Processing
time
Hours Days ~4x faster
throughput
Quality Consistent quality from high-purity
chemicals
Risk of contamination from Tar
1. Based on estimated BTU consumption of pitch coating to Forge Nano equipment electricity consumption
Material
loading
0.001 weight % 5-30 weight % >100x lower
CO2 emissions
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Phased approach
for up to 500MWh
Entry into Battery Value Chain
Intent to Directly Serve a Broad Range of Niche Applications and Partner/License for Large Applications
Auto
EV OEMs
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Cell Manufacturing
• Leading Li-ion battery formulation enabled by ALD
• Safest and highest quality cells
• Lower cost with higher performance
• Unlimited future roadmap
• America-only supply chain possible
• Active Supply and Development Agreements
Raw material
Chemical
Process
Cathode / Anode
production
Cell assembly
Final product
assembly
Consumer
Power tools
Consumer durables
Defense
Airforce, DOD,
Federal fleet
electrification
Industrial
ESS,
Marine,
IoT
Thrust #2: Forge Nano is Building a Battery Demonstration Facility
Battery pack
production
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Be mindful of constraints
• The demand is there (critical), we must figure out how to remove constraints
• Government to provide catalytic financing to get ball rolling
• Fund ready technology to reduce scalability constraints
• Incentivize partnerships to resolve manufacturing risk and speed up innovation adoption
• Incentivize co-location to reduce costs and shipping delays
• Improve upon permitting to reduce timing constraints
• Improve policy to ensure long term success
• Industry
• Focus on domestic needs
• Connect with right communities
• Work to reduce/remove constraints
Austin Devaney, Piedmont Lithium, NAATBatt 2022
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Constraints on US Li-ion Battery Production
UNCONSTRAINED DEMAND by 20xx
MATERIALS SUPPLY CONTRAINT
PERMITTING CONSTRAINT
CAPITAL CONSTRAINTS
(FINANCIAL, HUMAN, EQUIPMENT)
TECHNOLOGY CONSTRAINT
$$
$$$$
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US cell producers need to execute differently across to win in the market
Leverage existing chemistries to deliver scaled production now
Established
Supply chain
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Requirements for long-term, competitive US cell production
Must have path to maintain future performances needs
Improved
Performance
Don’t make an offering unless it is safe to use
Increased
Safety
Play on key American strength: Innovation
Lower cost
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Next Steps
• Set realistic timing expectations around constraints
• Capabilities
• Hardware
• Construction
• Existing supply chain difficulties
• Must support sustainable innovation plans
• Standardize testing and evaluation
• Can’t rely on administrations
• Must consider the competition
• China will do with batteries what Saudi Arabia does with oil
• Continue R&D, we’re good at that
• Integration of ready technologies (like ALD)
• Adapt tech from other markets (semiconductor)
• Must just get started (on parallel paths)
• Can’t hold our breath forever on step change technology (leap frogging)
• Need to find our way to the driver's seat of the supply chain (reduce risk)
• Safety, traceability, visibility, responsibility (think of agriculture)
https://www.shell.com/inside-energy/a-growing-role-for-sulphur.html
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