Raw Materials. System Architecture. Advanced Manufacturing. Engineered together
Estes is rebuilding the industrial base for high voltage battery systems on US soil. From raw materials to final form, fit and function -- under one roof.
Materials
Our Magnesium Thesis
Estes has been quietly innovating across all aspects of this incredible material: flame retardant alloys, an automotive scale forming process, and a multi-layer coating. Together, a domestic manufacturing capability for high-voltage battery systems – and beyond – built in the USA.
01
Alloy: MgCarbonit™
Estes’ proprietary magnesium alloy: 33% lighter than aluminum, thermally conductive, flame retardant. Two formulations: MgCarbonit60 (high ductility) and MgCabonit91 (high strength). Recyclable. 3rd party tested to FAA safety standards.
02
Forming: Giga-Thixomolding
Estes’ thixomolding press is a fully-electric light metal casting machine capable of producing some of the largest magnesium components in the world. Raw materials in, thermo-structural frames out. Up to 30kg of MgCarbonit material can be molded at one shot-per-minute.
03
Coating: Levius™
For all it’s benefits, magnesium corrodes. Estes’ proprietary Levius coating morphs magnesium surfaces into stable oxide ceramic, unlocking our ability to use MgCarbonit as a thermo-structural element in high voltage systems exposed to brutal environments.
Chemistry agnostic
82%
gravimetric conversion efficiency
50%
Description text
75%
fewer unique components
225
Wh/kg Delivered
LFP
155Wh/kg
Nickel
225Wh/kg
SILICONE
280Wh/kg
Scalability
DISTRIBUTED BMS ARCHITECTURE
Enables system redundancy
FUNCTIONAL SAFETY
According to ISO26262 up to ASIL-D
FLEXIBLE BATTERY PACK CONFIGURATION
Single & multi-string battery packs can be intermixed in a system
CYBERSECURITY
Certified to ISO 21434
Manufacturing
Cell-to-X: The best part is no part
Estes’ alloying, forming, and coating capability enables building the machine around – and from – the battery system. Passive and active thermal management strategies can be fully integrated into cell-to-airframe and cell-to-machine architectures, eliminating mass and cost from high-performance systems.
The full stack, on US soil.
From alloy to high-voltage system, every step of the Estes technology stack runs through a single manufacturing facility. Estes is actively seeking partnerships with companies who are interested in implementing magnesium into their own platforms. The next step is a technical conversation
What is the Levius Process?
Estes' proprietary Levius™ process is an end-to-end manufacturing and coating process for magnesium components. It integrates three steps: Estes' flame retardant MgCarbonit™ alloy mixing process, giga-thixomolding, and application of a multi-layer, protective coating that unlocks magnesium for high-voltage cell-to-pack battery architectures. Estes is growing its portfolio of patents pending and trade secrets which cover Levius™ processes, materials, and manufacturing recipes.
How does giga-thixomolding differ from conventional magnesium die casting?
Can Magnus™ integrate next-generation cell chemistries without an architecture redesign?
What certifications will the Magnus™ platform obtain?
Where is the Magnus™ platform manufactured, and what are its domestic content credentials?
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