Lithium-ion batteries have revolutionized energy storage, but inexpensive, truly long-duration batteries may still have a significant role to play in backing renewables and decarbonizing the grid. Form Energy is tackling that challenge with a new class of iron-air batteries. By oxidizing and reducing iron — essentially rusting and unrusting the earth's most abundant metal — Form is creating low-cost, multi-day storage that competes directly with natural gas peaker plants.

Mateo Jaramillo, CEO and co-founder of Form Energy, has spent over two decades in the battery industry, including building Tesla’s storage business. At Form, he’s leading the charge to bring these "E-peakers" to utilities across the country. The company recently achieved a major milestone: completing a 550,000 square-foot factory on the site of an old steel mill in Weirton, West Virginia.

In this episode, Mateo talks with host Lara Pierpoint about the grueling realities of scaling up manufacturing, why they chose to build in West Virginia, using AI to drive material science discovery and dig a data moat, and the immense logistical challenges of building the physical infrastructure of the clean energy transition.

Credits: Hosted by Lara Pierpoint. Produced and edited by Ross Kenyon, Anne Bailey, and Stephen Lacey. Sean Marquand is our technical director. Stephen Lacey is our executive editor.

The Green Blueprint is a co-production of Latitude Media and Trellis Climate. Subscribe on Apple, Spotify, or anywhere you get podcasts. For more reporting on the companies featured in this show, subscribe to Latitude Media’s newsletter.