Forge Nano breaks ground on North Carolina battery gigafactory

Forge Nano has broken ground on a major expansion of its lithium-ion battery manufacturing facility in Morrisville, North Carolina. The project aims to expand the existing site from approximately 10,000 square meters to nearly 30,000 square meters, creating a manufacturing campus of up to 315,000 square feet.

At full capacity, the facility is expected to produce approximately 3 gigawatt-hours (GWh) of battery cells annually. The expansion is designed to strengthen domestic supply chains for critical sectors, including defense, aerospace, and industrial applications, reducing reliance on foreign-controlled battery sources. The project is supported by up to $100 million from the U.S. Department of Energy.

Forge Nano is partnering with Samsung SDI to leverage manufacturing and operational expertise for mass production. Samsung SDI has also entered into a conditional agreement to purchase battery cells starting in 2028. The two companies are exploring the integration of Forge Nano’s Atomic-Armor coating technology into future Samsung SDI batteries. The facility is expected to create more than 250 jobs in North Carolina, with production slated to begin in 2028.