The Invisible Advantage

Formation Control Layer

The Formation Control Layer sits at the entrance of the gigafactory. It manages the very first charge cycles so that cells leave formation with consistent behaviour, predictable voltage response and stable early-life characteristics.

Instead of treating formation as a one-time black box, this layer enforces a structured, repeatable regime that works with existing racks and power hardware. Formation campaigns become shorter, more stable and easier to scale across lines and sites.

• • Stabilises early behaviour for both EV and stationary chemistries.
• • Reduces variance between cells at the point of formation release.
• • Increases line utilisation without rebuilding the formation floor.

Initial Activation Layer

The Initial Activation Layer focuses on modules, not single cells. It manages the first charge and discharge events at module level so that behaviour is aligned before packs are built and sealed.

By catching divergence early, this layer lowers the risk of mismatched modules entering pack assembly. OEMs gain smoother commissioning, fewer rework loops and a clearer link between factory data and in-field behaviour.

• • Aligns module behaviour before final pack build.
• • Improves traceability between formation, activation and end-of-line tests.
• • Supports both automotive and stationary module designs.

Battery Optimization Layer

The Battery Optimization Layer operates during real-world use. It keeps packs stable over thousands of cycles, targeting consistent range, power and ageing profiles.

The layer can sit in vehicles, BESS assets or industrial systems and coordinates with available factory data. Existing fleets become long-lived, more efficient energy assets without changing the underlying chemistry.

• • Extends useful life and stabilises performance over time.
• • Reduces internal imbalance and local stress inside packs.
• • Bridges factory commissioning and in-field operating data.

BESS & Grid Stability Layer

The BESS & Grid Stability Layer shapes how large storage systems import and export power so that substations, feeders and transformers see manageable profiles instead of violent swings.

Grid owners get better utilisation of existing infrastructure, with fewer protection trips and fewer unexpected interventions at critical nodes.

• • Reduces peak stress on grid equipment during charge and discharge.
• • Enables grid-friendly operation for utility and behind-the-meter projects.
• • Helps defer or resize grid upgrades at key substations.

Fast & Mega Charging Layer

The Fast & Mega Charging Layer governs very high-power sessions. It keeps cells, packs and chargers within safe operating envelopes while still delivering short stop times for drivers and fleets.

Instead of oversizing infrastructure, this layer makes fast charging a controlled, repeatable operation rather than a stress test on assets.

• • Supports short charging sessions without uncontrolled temperature rise.
• • Protects chargers, cables and upstream grid equipment from heavy swings.
• • Designed for corridor hubs, depots and fleet-centric charging sites.

Multi-Source Power Routing Layer

The Multi-Source Power Routing Layer coordinates energy coming from grid connections, on-site generation and storage. It decides when to draw from or feed into each source so that overall demand stays within preferred boundaries.

This is especially important for depots, ports and industrial campuses where several large assets share the same connection point.

• • Balances grid imports with solar, wind and local storage.
• • Supports tariff optimisation and connection-limit compliance.
• • Creates a consistent energy profile for multi-asset sites.

Energy Logistics Layer

The Energy Logistics Layer looks beyond a single site. It treats energy as something that can be moved and scheduled across mobile packs, marine platforms and remote hubs where grid build-out is slow or impossible.

It enables models such as mobile energy delivery, temporary construction power and islanded operations, all under the same Energy OS.

• • Supports mobile, marine and off-grid energy use-cases.
• • Links remote assets to the same architecture as factories and cities.
• • Creates new ways to deliver energy where fixed grids are constrained.

Energy Intelligence Layer

The Energy Intelligence Layer is the long-horizon coordinator of the GigaPulse™ stack. It looks across cells, packs, charging sites and storage assets to decide where, when and how energy should flow.

Instead of isolated projects, fleets and infrastructures become one connected energy network, using the same architecture from formation to grid level.

• • Coordinates decisions across all GigaPulse™ architecture layers.
• • Optimises energy use at fleet, portfolio and region level.
• • Creates a single intelligence layer for factories, grids and mobility.

Battery Life ↑

Traditional charging creates uneven SEI growth, internal stress and early capacity loss.

GigaPulse™ improves early-cycle stability using controlled current patterns, enabling a more uniform SEI layer and smoother ion movement across the full operating window.

Cells maintain their capacity longer, show less resistance growth and deliver a significantly extended lifespan across hundreds or thousands of cycles.

Heat Under Control

Heat buildup during charging is one of the main drivers of degradation and safety risk.

GigaPulse™ minimizes thermal stress by shaping current transitions and avoiding sharp spikes that destabilize the electrolyte and trigger local hotspots.

The result is lower temperature rise, more predictable thermal behavior and safer operation under high-load and fast-charging conditions.

Output ↑

Formation is the slowest and most energy-intensive step in battery manufacturing.

Uneven early-cycle behavior forces long soak periods and corrective cycling. By stabilizing ion flow and reducing variance between cells, GigaPulse™ allows formation to complete sooner with fewer corrective steps.

Manufacturers gain higher throughput and better economics without expanding formation hardware.

CO₂ & Waste ↓

High scrap rates, repeated corrective cycling and early pack replacements all add to CO₂ and material waste.

By stabilizing SEI formation, reducing variance and extending usable lifetime, GigaPulse™ lowers both process waste and replacement demand.

The same delivered service (km, kWh, flight hours, operating hours) can be achieved with fewer produced cells – directly reducing CO₂ per useful kWh.

OEM & Gigafactory ROI

For an automotive or cell OEM, GigaPulse™ is not a “nice to have” algorithm; it is a direct throughput and quality lever.

By shortening formation, reducing scrap and stabilizing early-life behavior, a single gigafactory can unlock additional GWh output without new buildings or racks. The same control layers can then be deployed in the field – extending pack life and reducing warranty exposure.

The economic effect combines capex efficiency in the factory with lower lifecycle cost in the vehicle and BESS fleets.

Grid Stability & Infrastructure Deferral

Ultra-fast charging, large BESS sites and high-power industrial loads all stress the grid. With GigaPulse™, charge events and power flows are shaped so that the same energy is delivered, but the peak demand and the rate-of-change seen by transformers and feeders are lower.

This does not only protect assets – it can directly defer or resize substation upgrades and new grid connections.

For investors, this translates into avoided capex and lower connection tariffs on critical nodes.

ESG Alignment & Impact

Every extra kWh of usable life extracted from a cell reduces the CO₂ per kWh delivered, the mining intensity per kilometer and the volume of waste over the asset’s lifetime.

Because GigaPulse™ acts on formation, first activation and in-field operation, it influences both the production and usage side of the ESG equation.

For ESG-focused capital, this allows clear, auditable indicators: fewer rejected cells, fewer replacements and lower CO₂/Wh across fleets and storage sites.

Long-Term Value & ROI Boost

Beyond a single factory or project, GigaPulse™ behaves like a long-lived Energy OS: once deployed, it can be extended across new chemistries, platforms, fleets and geographies without repeating the fundamental R&D cost.

Revenue can come from licenses, equipment, per-site deployments, per-fleet optimization and future Energy Logistics layers – all on top of the same core IP.

For investors, this creates compounding value: each additional deployment improves the data, strengthens the moat and lowers the marginal cost of expansion.