High energy domestic lithium-ion battery cells with aluminum cans
Forge Nano is developing high energy lithium-ion battery cells in the 21700 cylindrical format using aluminum cans to improve energy density and overall performance. The cells target aerospace, defense, microgrid, and portable energy storage applications. Testing includes electrical characterization across temperatures and discharge rates, thermal heat-rejection evaluation, and structural integrity testing to assess vent/burst behavior of the aluminum case. Technology readiness is TRL 6 with further validation and production integration planned.
Overview
Forge Nano is advancing lithium-ion battery technology by integrating aluminum battery cans into high energy 21700 cylindrical cells. This approach is intended to increase the cells’ energy density compared with traditional stainless steel can designs. The resulting cells are aimed at applications requiring high energy and efficient storage, including aerospace and defense, as well as commercial use cases.
Technical specifications
Key features:
- Utilizes 21700 cylindrical format for energy storage
- Uses aluminum battery cans to increase energy density
- Employs high energy anode and cathode formulations developed by Forge Nano
- Designed for aerospace, defense, microgrid, and portable energy storage applications
Testing and Validation:
- Electrical testing at various temperatures (-10°C, 25°C, 45°C) and discharge rates (C/3, C/2, 1C, 2C)
- Heat rejection testing to evaluate thermal performance under charge/discharge conditions
- Structural integrity tests to assess vent/burst ratio of the aluminum case
Technology readiness level
The technology is at TRL 6, indicating it has been demonstrated in a relevant environment. The next steps include further validation and integration into existing production lines to ensure performance and safety.
About Forge Nano Inc.
Forge Nano is a technology company based in Thornton, Colorado, that specializes in atomic-scale material engineering. The company developed a proprietary platform technology known as Atomic Armor, which utilizes Atomic Layer Deposition (ALD) to apply protective, uniform nano-scale coatings to materials. By executing a precise sequence of gas pulses and purges, the process forms thin, pinhole-free layers at the atomic level, effectively enhancing properties such as conductivity, thermal stability, and durability without adding significant weight or complexity to the underlying systems. Forge Nano operates as a vertically integrated manufacturer, producing both the ALD equipment and the end-product materials, such as lithium-ion batteries, using a predominantly U.S.-based supply chain.
The company's technology is critical for high-value industries, including defense, energy storage, and semiconductor manufacturing. By applying Atomic Armor, Forge Nano helps customers mitigate production yield losses in AI-era chips, increase the life and safety of battery cells, and improve the reliability of aerospace and defense hardware. The company serves as a strategic provider of domestic infrastructure for these sectors, with a portfolio of over 200 patents supporting its commercial operations. Through its specialized equipment and material solutions, Forge Nano works to solve performance limits that traditional chemical approaches cannot address, enabling advancements in data centers, quantum computing, and advanced communications infrastructure.
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