Battery Line 2 has successfully completed Factory Acceptance Testing (FAT), validating system performance under real operating conditions ahead of installation! This milestone reflects the disciplined, process-driven execution required to scale advanced manufacturing.
Line 2 is purpose-built to expand overall production capacity and incorporates key enhancements, including a single-piece flow configuration, increased process redundancy, and advanced pick-and-place gantry systems to drive faster cycle times and improved efficiency.
These design improvements, along with the Thorn Hill building layout, are expected to translate into meaningful gains:
1. Raw material travel reduced from approximately 2.09 miles to 0.29 miles —86% reduction
2. Line length reduced from approximately 478 ft (Line 1) to 288 ft (Line 2) — 40% reduction
Next stop: installation at the Eos Thorn Hill facility.
Solar and wind with battery storage has become a lot more cost competitive, a new IRENA report shows.
• $54–$82/MWh today (down from >$100 in 2020)
• New coal in China costs $70–85/MWh and new gas capacity costs more than $100/MWh globally
Since 2010, total installed costs declined by 87% for solar PV and by 55% for onshore wind. Battery storage costs fell even more sharply, declining by 93%.
In our earlier battery management system (BMS) architecture, a single imbalanced module could take an entire string offline—stranding energy across every module it was grouped with. We engineered around it. Oversized systems to deliver performance. Dispatched technicians when it happened. Accepted the downtime. It was the cost of doing business.
We decided it didn’t have to work that way.
Eos DawnOS™ is the result. A module-level BMS, built from the ground up for zinc-halide chemistry. When a module falls out of balance, the system can route around the issue. The string keeps running. Energy loss stays under 1%.
And because zinc is inherently resilient, most modules can recover on their own and reintegrate automatically.
No technician. No downtime.
That’s how installed capacity becomes usable capacity—and what five years of iterative development looks like.
For Eos Cubes with Z3™ modules already in the field, DawnOS can unlock trapped energy. Hardware, firmware, and software upgrades working together to bring deployed systems to full performance.
Full technical breakdown linked here: