US-based advanced lithium-ion battery manufacturer EGI Battery has established its first US battery manufacturing campus in Ann Arbor, Michigan.

The Ann Arbor facility positions EGI to deliver high-performance, lithium-ion pouch cell batteries in line with the National Defense Authorization Act (NDAA) that will power drones, electric aviation, aerospace, and emerging technologies such as humanoid robotics.

The first footprint of the Zeeb Campus includes approximately 15,000 square feet dedicated to initial manufacturing and laboratory operations, as well as 5,000 square feet of office space, and access to 130,000 square feet of total building capacity to support long-term expansion.

The facility has been designed in a phased scale-up model that allows EGI to expand production in measured, performance-driven stages, according to the company. EGI is targeting Site Acceptance Testing by the end of the first quarter and expects to start production during the third quarter of 2026.

Phase 1 deployment focuses on electrolyte filling, aging, sealing, folding, formation and grading operations. The initial production line is designed for 1 part per minute (ppm) filling and formation throughput, supporting up to 300,000 cells annually at full three-shift operation, which is equivalent to approximately 40 MWh of annual capacity. The 40 MWh capacity target is calculated using EGI’s commercial nickel manganese cobalt (NMC) lithium-ion pouch cell built for Class 1 and Class 2 drones delivering 35 Ah capacity.

The Phase 2 expansion, which is scheduled to begin in 2027, will vertically integrate additional core processes to include all stages from electrode making to cell assembly and final formation. Upon completion, throughput is expected to reach 2 ppm and support up to 600,000 cells annually for approximately 80 MWh of annual capacity.

EGI designs and manufactures battery cells using a technology portfolio that includes silicon-enhanced and graphite anodes as well as application-specific, client-bespoke battery formats designed to OEM system requirements.

The company is building the campus and its workflows to comply with ISO 9001 and AS9100 quality certifications while ensuring at least 95% NDAA-compliant materials by cost in 2028.

“The Zeeb Campus represents the operational foundation of EGI’s long-term manufacturing strategy,” said Thomas McGuckin, CEO and Founder of EGI Battery. “We are building scalable, high-yield production capabilities in Michigan to serve mission-critical industries that require a secure supply chain for domestically manufactured batteries. Our phased expansion model allows us to expand production capacity responsibly while maintaining performance, safety, and product quality leadership.”

Source: EGI Battery