Battery Production

Forge Nano is expanding its battery cell manufacturing operations in Morrisville, North Carolina. The site is expected to grow from just under 10,000 to approximately 29,000 square meters. According to the company, annual production capacity could reach up to 3 GWh at full utilization. Production is scheduled to begin in 2028. The project is receiving up to $100 million in support from the U.S. Department of Energy. The expansion is primarily aimed at battery cells for defense, aerospace, and industrial applications. Manufacturing equipment for the expanded battery production facility is expected to be delivered over the next two years. The timeline coincides with new sourcing requirements under the National Defense Authorization Act. These requirements are expected to apply to batteries used in defense applications starting in 2028. Forge Nano is therefore positioning the facility as a domestic source of lithium-ion cells. Samsung SDI Invests in Forge Nano Forge Nano is working with Samsung SDI to establish the expanded production operation. The battery manufacturer is expected to contribute manufacturing and operational expertise for high-volume production. The Morrisville facility is slated to manufacture both Forge Nano cells and Samsung SDI battery cells. Samsung SDI has also entered into a conditional agreement to purchase battery cells starting in 2028. In July, the company invested a total of $20 million in Forge Nano. This consisted of $10 million in Series D financing and $10 million in PIPE financing related to Forge Nano’s planned public listing. The two companies are also working on the potential integration of Forge Nano’s Atomic Armor coating technology into future Samsung SDI batteries. Source:https://ir.forgenano.com/news/news-details/2026/Forge-Nano-Breaks-Ground-on-Americas-Battery-Gigafactory-to-Strengthen-U-S–Defense-Supply-Chains/default.aspx

LG Energy Solution has started production at its new battery plant in Lansing, Michigan. At full capacity, the facility is expected to reach an annual production capacity of more than 35 GWh. The plant manufactures battery cells for stationary energy storage systems and electric vehicles. According to the company, LG Energy Solution has invested more than $2 billion in the site since 2022. The plant currently employs around 900 people. That figure is expected to increase to as many as 1,700 at full capacity. LFP Cells for Stationary Energy Storage In Lansing, LG Energy Solution manufactures large-format lithium iron phosphate cells. Its U.S. subsidiary LG Energy Solution Vertech integrates these cells into complete energy storage systems. The systems are intended for utilities, power grids, and commercial and industrial applications. Detroit-based DTE Energy is among the planned customers. LG Energy Solution plans to have more than 50 GWh of LFP cell production capacity in North America by the end of 2026. The company lists five production sites in the United States and Canada. By then, around 80 percent of LG Energy Solution’s global ESS capacity is expected to be located in North America. NMC Battery Cells for Toyota In addition to LFP cells, the plant produces higher-energy-density nickel-manganese-cobalt cells. These NMC cells are intended for Toyota. They are expected to be used in vehicles including the battery-electric 2027 Toyota Highlander. Source:https://news.lgensol.com/company-news/press-releases/5163/

CATL says it achieved carbon neutrality across its core operations by the end of 2025. The Chinese battery manufacturer aims to make its entire value chain carbon neutral by 2035. The company claims it is the world’s only battery manufacturer with carbon-neutral core operations at TWh-scale production volumes. 20 battery plants certified as carbon neutral According to CATL, 20 battery plants had received ISO 14068-1 certification by the end of 2025. Electricity used for its core operations reportedly came entirely from carbon-neutral sources. Since 2023, CATL says it has used more than 18 billion kWh of carbon-neutral electricity. Energy consumption per unit of output at its battery plants fell 28% compared with 2022. Carbon emissions intensity decreased by around 77% over two years. CATL puts the cumulative avoided emissions at more than 10 million metric tons of CO₂ equivalent. Supply chain moves into focus According to CATL’s calculations, more than 80% of its products’ lifecycle carbon emissions originate in the supply chain. The company says supply-chain emissions are more than five times higher than those from its core operations. CATL uses a platform based on its Carbon Chain Management System to track these emissions. It covers stages from mineral extraction and raw-material processing to component manufacturing. According to the company, the platform contains data from more than 100 key Tier 1 suppliers. Going forward, CATL plans to give greater weight to carbon footprints, renewable energy use, and energy consumption per unit of output when evaluating suppliers. An initial group of 30 key suppliers is participating in an emissions-reduction initiative. Source:https://cnevpost.com/2026/08/17/catl-core-operations-carbon-neutral-supply-chain-next/

Samsung SDI is acquiring General Motors’ 49.99 percent stake in the joint battery venture “SynergyCells”, becoming the sole owner of the cell plant currently under construction in New Carlisle, Indiana. The South Korean battery manufacturer announced the transaction on Tuesday, confirming an earlier report by Bloomberg. Samsung SDI cited changed market conditions since the joint venture was established, in particular slower-than-expected growth in US electric vehicle demand, as the reason for the restructuring. Partnership was announced 2023 GM and Samsung SDI announced their partnership in April 2023 and finalized the 3.5 billion US dollar joint venture in 2024. The roughly 680-acre site was slated to produce prismatic cells with nickel-rich NCA chemistry under Samsung’s PRiMX brand from 2027, with an initial annual capacity of 27 GWh, expandable to 36 GWh, and more than 1,600 jobs. Missing EV demand Recently, however, the project had stalled: in view of weakening EV demand, the two partners paused construction earlier this year. The building shell has been completed, but no production equipment has been installed so far. According to Bloomberg, GM has invested around 300 million US dollars in developing the site to date. Samsung SDI will complete the plant and produce BESS Samsung SDI now intends to complete the plant on its own and initially produce batteries for stationary energy storage systems (ESS) in order to tap into the fast-growing US storage market. The facility will be the company’s first wholly owned production site in North America. The strategic partnership with GM is set to continue nonetheless, including the joint development of next-generation prismatic cells. GM withdraws from cell manufacturing For GM, the sale marks the latest step in a gradual withdrawal from in-house cell manufacturing capacity: in 2025, the automaker had already divested its stake in the nearly completed Ultium cell plant in Lansing, Michigan, to LG Energy Solution. GM continues to operate two Ultium Cells plants together with LG Energy Solution, where production of LFP cells has recently started as well. SourceReuters, Samsung SDI

Chinese battery manufacturer CALB is overhauling its quality and safety processes following reports of swollen battery cells in GAC Aion vehicles. According to a report by Chinese media outlet Auto Time, the changes affect manufacturing, traceability, and the company’s quality management structure. The overhaul follows the “Banana Battery” controversy, which emerged in July. According to the report, CALB is tightening manufacturing tolerances, expanding moisture monitoring during cell production, and improving the traceability of production batches. The company is also reviewing materials and formulations used in 2022 and 2023 and discontinuing formulations with lower safety margins. Quality Department Gains More Authority CALB is also introducing organizational changes. According to Auto Time, the company’s quality department will have the authority to block production batches that fail to meet internal standards. In addition, CALB has established a dedicated quality team for passenger vehicle customers that will analyze battery management system (BMS) data together with automakers. Response to the “Banana Battery” Controversy The measures follow issues involving 177-Ah lithium iron phosphate (LFP) battery cells used in GAC Aion S vehicles. After accumulating between 150,000 and 300,000 kilometers (93,000 to 186,000 miles), some vehicles reportedly experienced cell swelling, electrolyte leakage, and power loss. GAC Aion subsequently extended the battery warranty for affected vehicles to eight years or 300,000 kilometers (186,000 miles). CALB said it would assume responsibility for battery cell quality. Source:https://cnevpost.com/2026/08/06/calb-banana-battery-quality-overhaul/

Samsung SDI plans to begin production of prismatic lithium iron phosphate (LFP) battery cells for stationary battery energy storage systems (BESS) in the US in October 2026, according to the company. The production line is currently undergoing mass production quality validation, with the first deliveries of the Samsung Battery Box (SBB) 2.0 scheduled before the end of the year. At the same time, Samsung SDI expects demand to exceed available production capacity from 2028 onward. The company announced last year that it aims to establish 30 GWh of annual BESS cell production capacity in the US by the end of 2026. Against this backdrop, Samsung SDI says it is already evaluating options to expand capacity further. Non-FEOC Supply Chain a Key Focus According to Samsung SDI, it has secured LFP cathode materials and other key components through partnerships with suppliers in South Korea and the US to establish a supply chain that complies with US Foreign Entities of Concern (FEOC) requirements. The effort follows changes to US tax incentive rules that restrict eligibility for projects using certain imported battery cells. The company says orders received to date already cover a substantial portion of its planned production capacity through 2029. During the second quarter, Samsung SDI also signed long-term supply agreements with US BESS customers, although it did not disclose details. In addition to LFP technology, the company is developing sodium-ion batteries for data centers and large-scale energy storage systems but has not provided a commercialization timeline. Source:https://www.energy-storage.news/samsung-sdi-on-track-with-us-lfp-cell-production-expects-demand-to-outstrip-production/

Altech Advanced Materials AG has discontinued the CERENERGY battery project in Saxony. According to the company, the decision followed an unsuccessful nine-month search for a strategic partner. The company said the prospects of securing financing and bringing the project into operation had become so limited that further operating expenses could no longer be justified. The project was intended to produce sodium-alumina solid-state batteries for stationary energy storage applications. Developed as a joint venture between Altech and the Fraunhofer Society, it was designed to supply battery systems for electricity grids and the storage of energy generated from wind and solar power. The initial plan called for an annual production capacity of 100 megawatt-hours, with expansion planned in later stages. Project Company to Be Liquidated The decision also means the liquidation of Altech Batteries GmbH, the company that holds the project’s assets. The site in Spreetal is to be sold back to the local municipal authority. The patent rights for the CERENERGY technology will remain with the Fraunhofer Society, which owns a 25% stake in the project company. Sources:https://www.altechadvancedmaterials.com/wp-content/uploads/2026/07/2026-07-30-CERENERGY-Projekt-Eingestellt.pdfhttps://www.altechadvancedmaterials.com/wp-content/uploads/2023/04/Geschaeftsbericht-AAM_2022_fin_Upload.pdf

The European Commission has launched a funding call under the Battery Booster Facility. The program offers up to €1.5 billion in interest-free loans for battery cell manufacturing projects in the European Economic Area (EEA). It is financed through the Innovation Fund, which is funded by revenues from the EU Emissions Trading System. Applications are open until September 30, 2026. Support for the Production Ramp-Up Phase The loans target projects in the ramp-up phase between pre-series production and full commercial operation. According to the European Commission, the funding is intended to help companies expand production more quickly and attract additional private investment. Eligible projects must manufacture battery cells for electric vehicles and be located in the EEA. Projects must already be in the ramp-up phase when the call opens. They must also represent the applicant’s first full-scale commercial battery cell production project for electric vehicles anywhere in the world. In addition, each project must have a planned annual production capacity of at least 10 GWh. Successful applicants may receive interest-free loans covering up to 60% of eligible costs. Funding is capped at €500 million per project. The Battery Booster Facility is part of the EU’s broader strategy to strengthen Europe’s battery industry. According to the Commission, the strategy also includes measures to encourage investment, strengthen the upstream battery supply chain, support innovation and skills development, and improve coordination across Europe. Sources:https://single-market-economy.ec.europa.eu/news/commission-seeks-projects-fund-under-battery-booster-facility-2026-07-28_enhttps://single-market-economy.ec.europa.eu/calls-proposals/battery-booster-facility-call-proposals_en

U.S.-based battery developer Factorial Energy and South Korean battery manufacturer SK On plan to collaborate on solid-state battery technology. The goal is to evaluate whether and how SK On’s existing manufacturing facilities could be used to produce solid-state batteries. The specific terms of the collaboration are expected to be defined in future agreements. The partnership will focus on the technical evaluation of Factorial’s FEST solid-state battery technology. Existing Manufacturing Capacity in Focus According to the companies, the collaboration will examine the manufacturing requirements for solid-state batteries and assess whether existing lithium-ion battery production lines are suitable for the technology. Factorial aims to pursue a capital-light approach by leveraging existing manufacturing infrastructure rather than building new production facilities. SK On has an annual global production capacity of more than 200 GWh, including approximately 100 GWh in the United States. Its U.S. manufacturing footprint includes facilities in Commerce, Georgia, as well as operations in Tennessee. Assessing Industrial Feasibility The collaboration will initially focus on technical feasibility and manufacturing requirements. Whether it will lead to commercial-scale production remains uncertain. According to Factorial, this is the company’s first manufacturing-focused partnership with a global battery producer. The companies also plan to explore potential applications for solid-state batteries in mobility and other high-performance markets. Source:https://factorialenergy.com/press-releases/factorial-and-sk-on-sign-mou-to-explore-solid-state-battery-manufacturing/

BMW plans to begin series production of high-voltage batteries for the all-electric BMW iX5 at its new Woodruff plant in South Carolina in December 2026. According to the company, test and pre-series batteries are already being produced at the facility. The batteries will then be shipped to the nearby Spartanburg vehicle plant, where the iX5 will be assembled. The Woodruff plant is part of BMW’s global “Local for Local” production strategy, under which batteries are assembled close to the company’s vehicle manufacturing plants. In addition to Woodruff, BMW has established or is establishing similar battery assembly sites in Germany, China, Mexico, and Hungary. AI and digital planning intended to improve battery assembly According to BMW, the Woodruff plant uses AI-supported production processes, digital twins, and virtual reality applications. More than 300 employees and 250 robots are expected to support the assembly of high-voltage batteries. The company says all production steps are continuously monitored and documented in real time. AI assistants are intended to analyze the resulting data and support manufacturing operations. Gen6 battery with 800-volt architecture for the BMW iX5 The batteries are based on BMW’s sixth-generation high-voltage battery technology. Cylindrical battery cells are integrated directly into the battery pack using the company’s Cell-to-Pack design. The battery-electric BMW iX5 will feature BMW’s sixth-generation eDrive technology with an 800-volt architecture. According to the company, the high-voltage battery provides a usable energy capacity of 144 kWh in the U.S. and 141 kWh in Europe, making it the largest battery ever offered in a fully electric BMW model. Source:https://www.press.bmwgroup.com/deutschland/article/detail/T0459239DE/erste-einblicke-in-die-produktion:-bmw-group-werk-woodruff-montiert-die-hochvoltbatterien-fuer-den-neuen-bmw-ix5