An overview of Ensurge's solid-state technology foundation and the changes happening as we move from lab prototypes to reliable, production-ready products.

At Ensurge, we're writing the next chapter in solid-state microbattery technology. Our mission is clear — to turn proven technology into scalable, high-performance products that customers trust and markets reward. This shift from a prototype mindset to production execution defines a new era of growth for Ensurge Micropower.

From Platform to Product - Built for Scale and Impact

Ensurge's solid-state microbattery technology is built on our Micro Power Platform (MPP), a proprietary design that provides exceptional volumetric energy density, safety, and flexible form factors for applications ranging from 1 to 100 mAh.

The technology stack includes a set of interchangeable platforms, such as layers of either 75 µm or 10 µm stainless steel, which can be manufactured using standard methods and integrated through a unified architecture to deliver application-specific performance.

With this, we are on track to achieve over 600 Wh/L volumetric energy density with our initial 10 µm launch product — nearly twice that of lithium-ion alternatives. We have also demonstrated higher pulse discharge rates of at least 5C/12.5C, enabling microbatteries to support improved connectivity and signal capabilities for high-current applications such as LEDs used in wearables.

Looking ahead, a new generation of ceramic substrates will also be integrated into the technology stack. Through a recently announced joint development agreement, Ensurge and Corning Incorporated will collaborate to integrate Corning's Ribbon Ceramic materials into Ensurge's microbattery design, providing an ultra-high-energy-density product line extension.

The collaboration with Corning — one of the world's leading material science innovators — is the strongest external validation of Ensurge's technology so far. Corning's direct involvement lends global manufacturing credibility and speeds up Ensurge's journey from prototype to commercial production.

Unlike traditional lithium-ion cells that use flammable electrolytes, Ensurge's solid-state design prevents thermal runaway and provides stable performance over a wide temperature range. Our cells also operate without external pressure, enabling new form factors for space-constrained applications such as hearables, medical implants, sensors, and other IoT edge devices.

Importantly, unlike other solid-state lithium batteries, Ensurge microbatteries do not require external pressure to perform optimally. This greatly expands the options available in form-factor design and integration, making our batteries an ideal choice for powering devices where space is at a premium — leaving Ensurge well-positioned to serve the fast-growing markets for wearables, hearing devices, remote sensors, and the broader IoT ecosystem.

A strong product is only valuable when it can be produced at scale. Ensurge technology is designed for that purpose. We utilize proven roll-to-roll manufacturing methods to deposit core battery components onto thin substrates. The cells are then accurately cut, stacked to meet capacity needs, and assembled using common Surface Mount Technology (SMT) processes. While our manufacturing approach is capital-efficient, it is also highly scalable for mass production of custom form factors.

The San Jose pilot line now consistently produces repeatable, high-quality production runs, showing that Ensurge is putting the right processes in place for industrial scaling and tier-one qualification.

The Ensurge technology platform is one we've heavily invested in over the past few years. Currently, we're manufacturing cells to order for customers and internal projects at our San Jose pilot facility. Overall, we're at a pivotal point — ready to scale with partners and customers as our main markets grow with the rise of AI.

Tailoring Technology to Customer Needs

Under CEO Shauna McIntyre's leadership, Ensurge is establishing a new benchmark for micro-scale energy storage. This involves a sharp focus on delivering production-quality, commercially viable products that pass strict validation standards. While Ensurge was once prototype-focused and emphasizing speed and learning, we now emphasize quality, reliability, and repeatability—delivering on customer validation packages that foster trust for large-scale production.

We now adopt a disciplined approach aligned with how our customers operate — multi-stage development programs with increasingly rigorous standards at each phase. This collaborative method guarantees that each customer gets a customized solution built on our shared architecture: specific layer counts, form factors, and mounting attachments that fulfill their unique requirements.

This approach isn't flashy — it's designed for trust and long-term partnerships. Our goal is straightforward: to provide high-quality products that deliver as promised, reliably and at scale.

Building Trust Through Quality

The shift from a prototype mindset to a commercial mindset is more than operational — it's cultural. It requires thorough testing, open communication, and a steadfast dedication to delivery.

Our recent customer shipment demonstrates this progress. These are not just concept devices; they are production-intent samples validated in environments where lithium-ion batteries typically fail — including medical device sterilization and semiconductor equipment calibration. The microbatteries are hermetically sealed to replicate real-world wearable conditions like hearing aids and are tested by partners who require proof, not just promises.

"Earlier testing by Ensurge and our customers has validated the capability of our technology," says Shauna McIntyre. "Now we're taking it to the next level — testing high-temperature operation and integration in applications where performance and safety cannot be compromised."

The microbattery market is changing quickly. As AI shifts from data centers to the edge, devices with limited space need higher power density, longer lifespan, and better safety. Ensurge's solid-state microbatteries are designed to meet this demand — and we are working with discipline and consistency to deliver.

Commercial Readiness and Outlook

With proven technology, repeatable manufacturing, and Corning as a strategic collaborator, Ensurge is entering its commercialization phase. 2026 will mark the shift from validated prototypes to large-scale production, enabling the next generation of AI-enabled and medical devices.

If you're qualifying power devices for consumer, medical, or connected applications, request a sample or schedule a technical discussion with Ensurge at www.ensurge.com/contact .