Aspen Aerogel and GM

"The Equinox EV Is The Homerun-Hitter GM Needed

Nearly one-third of GM’s U.S. EV sales in Q3 came from one model: the Chevy Equinox EV. The automaker sold 9,772 units of the Equinox EV during its first full quarter on sale."

https://insideevs.com/news/735766/gm-ev-sales-q3-2024/

Aspen Aerogel insulation is used on every GM ultium vehicle. The new Equanox EV is build on the ultium plafrom, they have 300 mile range and starts at $35,000. It can be had for as low as $27,000 with tax credits.

I added to my ASPN position today.

Kindest regards,
Happyhunting

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Interestingly, GM just announced that they’re terminating the “Ultium” brand for their batteries. Multiple articles online, here’s one:

https://insideevs.com/news/736598/gm-to-dump-ultium-brand-name/

Now, Kelty said the automaker plans to incorporate different battery chemistries and varying cell shapes to tailor them to particular models

How that affects Aspen Aerogels is unknown to me.

Kelty said all of this is meant to “significantly” reduce battery weight, drive down costs and make manufacturing less complex. GM last year said it was abandoning its goal of selling 400,000 EVs by mid-2024—now its on track to produce and deliver about 200,000 EVs this year.

So, even if they keep Aspen Aerogel, with an output half of what they previously said the short term may not be as bright.

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“GM’s sales were assisted by a roughly 60% year-over-year increase in EVs during the quarter, to roughly 32,100 units sold. Still, EVs made up only 4.9% of the company’s total third-quarter sales.” (Oct 1 2024)

Aspen reports in a few weeks. I think they will post strong revenue growth. I am looking forward to reading the confrence call to see what they will say about terminating the Ultium brand. The next generation battaries should be safer, and probably won’t need Aspen Aerogel insulation. To my thinking thats their biggest upcoming risk. For now i plan to hold.

Kindest Regards,
Happyhunting

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Why do you assume they won’t need Aspen Aerogel? Do the new batteries solve for thermal runaway?

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Well if they move away from Pouch batteries (to cylinder batteries as per Tesla), that will eliminate Aspen Aerogel but I’m not sure if that is the plan.
Ant

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I think people are misreading this big time. I’m quoting from the link @Smorgasbord1 shared.

Ultium concerns

Kelty admitted the challenges GM faced in scaling up battery production but added, “I can confidently tell you that the manufacturing problems we faced at the end of last year are behind us.”

GM increased its battery module production by 10 times compared to the last year and its Ohio-based JV with LGES is on track to produce 100 million cells by the end of this year. GM is also building a new $3.5 billion battery plant in Indiana in partnership with Samsung SDI to develop nickel-rich prismatic cells.

→ So this tells me they have rapidly expanded Ultium production in the last year as everything quoted above is on the Ultium platform. That also gels with what they told us in their ER (see below). Note also that Toyota and Honda are still in the early phases of ramping.

Concern about other platforms and prismatic cells

Here is the quote from the OP:

That will change for future models as GM prepares to include high-nickel, mid-nickel and lithium-iron-phosphate (LFP) cathodes. That includes using the current pouch cells for some models and also using the easier-to-assemble prismatic cells for others.

→ This tells me that they will move from a one-size fits all Ultium platform to many different platforms, and that they will do prismatic cells in addition to pouch. This, to me means there will be more opportunity for ASPN, not less. Prismatic cells is a CORE FOCUS AREA of theirs, as per the ER material from Q2:

And, about these new non-pouch batteries of theirs, here is another quote from that article:

The new center is expected to be up and running by 2027 and together the two facilities will be able to develop new packs and get them ready for production in 18 months.

So by my reading of this, we’re talking about the new cells being ready 18 MONTH AFTER 2027!! So not only will the new cells also require Pyrothin, they will only start in 2029

And lastly the concern about GMs volumes being down to 200k is old news. In ASPN’s Q2 ER they in fact took the 200k number and LOWERED it to 180k for their guidance.

-wsm

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Up thread when I referred to next generation batteries, I was referring to “those utilizing solid-state technology. They are expected to be significantly safer than current lithium-ion batteries, as they replace flammable liquid electrolytes with non-flammable solid electrolytes, reducing the risk of fire.”

Currently there is tremendous research going on the improve EV battery range and safety. To my way of thinking, better, safer EV batteries are very likely to become a reality, its just a question of how long it will take. In the mean time I have a medium size position in Aspen Aerogel.

Kindest Regards,
Happyhunting

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The amount of PyroThin needed is limited by the number of battery modules being made, which is limited by the number of EVs being sold. Unless ASPN’s customers sell more cars, they won’t be using more PyroThin. And we know GM’s EV estimates are less than half what they were not that long ago - even if that’s “old news” it’s still relevant to ASPN’s near-term revenue growth.

My understanding is weak, but I believe Aspen Aerogels is placed between cells (or modules), as part of building up the battery pack and not used in creating the actual cells.

There is no guarantee that the design of the new modules using new cells will have the same thermal barrier requirements, as there could be other ways to cool and prevent thermal runaway in new battery packs.

I looked at a Feb '24 powerpoint and pulled some information out. First is understanding the total business:
Screenshot 2024-10-10 at 10.57.53 AM

Of the Thermal Barrier Revenue, it’s almost all from one customer - GM. Even Honda is using GM’s Ultium batteries today, and with production/development of those stagnating or declining, Honda may choose something else for its future EVs.

Aspen Aerogels itself says growth in its largest segment (Thermal Barriers) relies on GM selling more of these EVs:

And talks about these as that’s business’ “upside drivers”:
Screenshot 2024-10-10 at 10.56.42 AM

The first of which is now a big question as GM is moving away from Ultium production.

As for it’s other “Energy Industrial” business:
Screenshot 2024-10-10 at 10.56.50 AM

I know nothing about that business or its potential growth, but it’s less than ⅓ the size of the Thermal Barrier business.

Back to EVs, GM is moving towards including LFP and using less modules per pack:

And an earlier deck from ASPN has this quote:
Screenshot 2024-10-10 at 11.09.40 AM

Seems like less thermal barriers will be required per EV. But, I could be wrong.

It strikes me that ASPN has a big customer concentration problem, being very much dependent on one customer - GM. But not only is GM not growing its EV business, it just introduced major uncertainty into its use of Aspen Aerogels’ products.

Maybe having been bitten by single market (EV) concentration with AEHR Test Systems I’m being too gun-shy here.

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One of the topics that gives me optimism for ASPN’s near term revenue is that the US EV markets needs to grow a lot by 2026 to meet the Zero Emission Vehicle regulations adopted by many states. Right now the US market is scratching 8% so the EV market will need to grow substantially for Original Equiptment Manufactors (OEMs) to meet state requlatory requirements and avoid fines.

Even if ASPN’s products are not needed for GM’s future battery designs, GM will still need to use Ultium battery platform for the next few years and the next few years represents a lot of growth with these state requirements.

Here is a summary of state requirements:

Several U.S. states have set electric vehicle (EV) sales targets by 2026, largely following California’s Advanced Clean Cars II program. These states have adopted or are in the process of adopting California’s Zero-Emission Vehicle (ZEV) mandate under Section 177 of the Clean Air Act. This mandate requires a certain percentage of new vehicle sales to be zero-emission vehicles (ZEVs), including electric and hydrogen fuel cell vehicles, or plug-in hybrids. The targets vary, but for 2026, they generally align with the California targets. Here’s a breakdown of some of the states that have adopted or are adopting these targets:

1. California

  • Target for 2026: 35% of new car sales must be ZEVs or plug-in hybrids.
  • Long-term goal: 100% of new vehicle sales to be ZEVs by 2035.

2. Oregon

  • Target for 2026: 35% of new vehicle sales must be ZEVs or plug-in hybrids.
  • Oregon follows California’s ZEV regulations closely.

3. Washington

  • Target for 2026: 35% ZEV sales.
  • Washington adopted California’s ZEV standards and set a goal for 100% zero-emission new vehicle sales by 2035.

4. New York

  • Target for 2026: 35% of new vehicle sales must be ZEVs.
  • New York has followed California’s emission standards and aims for 100% ZEV sales by 2035.

5. Massachusetts

  • Target for 2026: 35% ZEV sales.
  • Massachusetts is another state that has adopted California’s ZEV mandates.

6. Colorado

  • Target for 2026: 35% of new vehicle sales should be ZEVs.
  • Colorado has adopted the ZEV mandate and follows California’s emissions standards.

7. Vermont

  • Target for 2026: 35% of new vehicle sales must be ZEVs.
  • Vermont also follows California’s ZEV mandates.

8. New Jersey

  • Target for 2026: 35% ZEV sales.
  • New Jersey has adopted California’s ZEV regulations and has long-term targets of 100% ZEV sales by 2035.

9. Maine

  • Target for 2026: 35% of new vehicle sales must be ZEVs.
  • Maine follows California’s vehicle emissions standards.

10. Connecticut

  • Target for 2026: 35% ZEV sales.
  • Connecticut is following California’s mandates and aims for full ZEV sales by 2035.

11. Rhode Island

  • Target for 2026: 35% ZEV sales.
  • Rhode Island is following California’s ZEV standards closely.

12. Maryland

  • Target for 2026: 35% of new vehicle sales must be ZEVs.
  • Maryland is aligned with California’s regulations and aims for a full transition to ZEVs by 2035.

Other States Considering or Adopting ZEV Rules

Several additional states are either in the process of adopting ZEV rules or are considering doing so, which would mean similar targets for 2026. These include states like Minnesota, Nevada, and Virginia.

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I disagree…the numbers do as well.

GM is massively growing it’s EV business - how can a 46% sequential growth in Q3 be viewed as “not growing”?? And they are ramping up Ultium production with no uncertainly introduced as far as I can see.

In Q3 2024 GM EV sales set another record for the quarter, up 60% year-over-year to 32,195 total deliveries, up 46% from the second quarter. As a result, GM’s share of the total U.S. EV market increased to 9.5% from 7.1% in Q2. That’s a 2.4% share gain in one quarter!

Here is the source. I was posted by @Happyhunting as well.

And this is what the GM CEO said on 23 July in their ER:

As I said before our EV portfolio is growing faster than the market now that our module issues are resolved and we are scaling production. Our early sales are mostly incremental - about 54% of customers are new to GM and we’re working to increase our conquest rate by raising awareness and launching new models. Our best-selling EV so far this year is the Cadillac LYRIQ and it is now the market leading luxury EV in 22 states including Florida, Texas, and Michigan. The GMC Hummer EV and the Chevrolet Blazer EV are also building momentum.
To unleash the next cycle of EV growth we’re scaling production of the Chevrolet Equinox EV with its unique combination of performance, technology, range, and affordability. We delivered our first 1,000 units late in the second quarter and the reaction from customers, dealers, and the media is very strong. One product reviewer said, Chevy seems positioned to grab a piece of the pie that no one else has quite grabbed onto yet, and we think that is spot on.
Then over the next several months, GMC will launch the Sierra EV, and the Cadillac LYRIQ will be joined by the OPTIQ, Escalade IQ and CELESTIQ. We’re especially excited about the OPTIQ. Car and driver said it nails the compact luxury SUV formula. Then next year, when we follow with the CELESTIQ, Cadillac will have a beautifully designed EV in every global luxury SUV segment. We’re going to focus on winning new customers with these nameplates, as well as with the next generation Chevrolet Bolt EV because they represent the largest growth opportunities for us.
But we’ve also made adjustments to ensure we have a balanced approach as the market develops. This includes deferring Buick’s first EV which had been planned for 2024. As we’re expanding choice, other barriers to EV adoption like public charging access are also improving. We are working to finalize commercial agreements with Tesla to give our customers access to their charging network. The IONNA fast charging venture we joined is expected to bring its first chargers online before the end of the year, and customers are telling us the drive-through plazas we’re rolling out with Pilot company are the best public charging experience out there.
As excited as we are about our portfolio, we are committed to growing responsibly and profitably in any demand environment. Over the next few years, third-party forecasters now see the EV market growing steadily, but more slowly than it did over the last few years. As a result, we are adjusting our spending plans to make sure we’re capital efficient and moving in lockstep with customers. For example, our Ultium cells joint venture continues to ramp up domestic battery cell supply this year, which is helping drive profit improvement in our EV portfolio.
As we go forward, we’re going to bring additional capacity online in a measured cadence. This will enable us to better optimize our battery chemistry and form factors to meet our customers’ needs on cost and range. We’ve also decided to reopen the Orion assembly as a battery electric truck plant in mid-2026. The new timing is six months later than our plan heading into the year. We’re confident that we can meet customer demand for standout EV trucks in the interim by leveraging the production capability and flexibility we have in factory zero. We will also continue to take advantage of the flexibility we have to mix production between ICE and EV at key plants.

That does not sound like a company who is “not growing its EV business”!! I don’t know where the narrative comes from.

The US EV market is growing slower than the heightened expectations that prevailed a while ago imo, but that is in line with the rest of the auto business. high interest rates dampen demand for big ticket purchases like cars. Has always been the case and this time was no different. But ASPN didn’t have heightened expectations in their recent forecasts. And now interest rates are coming down. Which will have the opposite effect on big ticket purchases.

Also globally EVs are still growing massively. This is a secular shift that is happening. Here is a global view that I managed to find. with a google sheet with the detailed info. Note that this excludes hybrids and so won’t tally with market-wide numbers for the US.


Also remember that GM is just getting going with their EV launches - they are starting from a very low base and now ramping aggressively, albeit less agressively than they would have done a couple months back. But still, they are taking share in a secular growth market. So yes, there is customer concentration for ASPN. But that customer is ramping quite nicely.

In addition, ASPN have other customers that are even earlier in the ramp-up: Honda, Toyota, which should in time reduce customer concentration.

And then we have other nameplates that have not even started registering in the ASPN numbers but are already in the planning/rollout phases: Stellantis, Scania. And then we have the potential of another OEM using ASPN (BMW? Mercedes?).

I’m going to finish my response by pointing all who wish to make a decision about owning ASPN to this (fairly long) comment in the Q2 ER from the CFO about the longer term. I think that is the investment thesis in a nutshell. If you believe him - buy. If not - don’t.

Before handing the call back to Don, we thought it’s important to take a look at what’s happening in the US electric vehicle market, our in-production OEMs mostly participate in, so that we aren’t rattled by the day-to-day headlines of exuberance or gloom. There just doesn’t seem to be an even keeled view out there. So we spent some time looking at the year-to-date market ourselves.

Let’s just face it. The US EV market didn’t grow year-to-date through the end of July relative to last year in the US. It’s only up around 1%, which is comparable to the growth rate of overall new vehicle sales. We foresaw this in early 2023 as we were planning for 2024, considering the effect of rising interest rates.

This fact is a key ingredient in developing our 2024 revenue baseline. Still though, EVs made up around 7% of the market and over 1.3 million EVs are expected to be sold in the US this year. So this has become a meaningful part of the market. Within it, there are some obvious share winners and losers. And as we started our EV thermal barrier business from zero in 2021, supplying newly developed platform in nameplates, we are benefiting from the demand gains of the OEMs that we supply.

PyroThin is equipped on six out of 10 new EV nameplates that have been introduced in the US in 2024 and those vehicles that were developed before we had a cell-to-cell solution are aging and losing share versus a range of fresh nameplates from OEMs that are gaining share. At this point, PyroThin is equipped on 100% of EVs sold by GM, Toyota and Honda in the US. These OEMs are only scratching the surface of what their share can be relative to their overall position in the entire new car market and the scale of their distribution. We believe that they will continue making gains as they launch new nameplates and offer attractive incentives on these vehicles to drive volume.

The need to produce EVs at a rate that properly enables the absorption of fixed manufacturing costs is, in our mind, expected to drive production rates in the second half of 2024 more than demand. The only thing more expensive than incentives up to a point is running at below 50% of one’s capacity.

I’ll let you spend more time with this slide on your own time. But when we look at the EV market in 2024, we continue seeing opportunities for additional sell-through within the OEMs that we supply, thanks to an interesting circular reference of higher production volumes needed to deliver profitability and higher incentives needed to drive those volumes.

Yes, what @stewaj1 said above is exactly what the CFO spent quite a bit of time on the most recent ER:

Thinking longer term and moving to slide 8, it’s worth remembering why OEMs built up all of this capacity to make EVs in the first place. Understanding the regulatory environment in the U.S. around emissions and fuel economy standards is important. As a guided investment that was made over the last four to five years within OEMs in preparation of tighter standards that will ramp up this next year.

I won’t bore you with all the details but U.S. new vehicle emissions and fuel economy regulation is driven by 2 major federal regulatory agencies. The Environmental Protection Agency or EPA and the National Highway Traffic Safety Administration or NHTSA. At the state level for 18 states that make up over 40% of new vehicle sales, including California this is driven within the California Air Resources Board or CARB standards.

Neal would be happy to point you in the direction of good reading material to understand these standards in detail. These agencies can enforce fines, sue or enforce penalties on OEMs who do not comply with their standards, and, therefore, impact the profit potential of currently lucrative sales.

Focusing on the EPA, when looking at 2026 to be minimum compliant with these regulations, the industry would need to reach roughly 15% EV sales mix, up about 7 percentage points from the current penetration or more than doubling. This includes the exhaustion and rollover of emissions credits purchased or generated from the sale of EVs in prior years.

General Motors, for example, would need to quadruple the CV penetration from 4% in July of 2024 to around 16% by 2026 to be barely compliant. It is estimated that Ford would need to triple its CD mix from its current levels also barely comply with the EPA submissions regulations.

If we go to what will be our next most important market after the US, Europe, the CO2 emissions there get even more stringent for OEMs, and that is why we see a lot of new programs from those OEMs in our core pipeline.

As we built up our thermal barrier business, we’ve met not only with teams inside the OEMs that are working to address thermal runaway in batteries for all form factors and chemistries but we’ve also met planning teams that are making sure that OEMs are positioned to comply with these regulations in 2025, 2026 and beyond.

OEMs take these regulations more seriously than one would think from reading the press or investor relations materials. And this is what continues giving us the conviction to keep investing in this market, particularly now that our operating model is being validated on quarter after another.

So, in summary here is my view:

  1. GM, ASPN’s key customer, is massively growing their EV business and taking share in a growth market
  2. Ultium production is scaling up big-time.
  3. ASPN’s pyrothin will be used in other form factors and chemistries of batteries too, because thermal runaway is a risk in all batteries. So GM deciding that a one-size fits all approach to batteries is not their future, is a nothing burger.
  4. GM’s move towards non-Ultium batteries will take time
  5. Toyota and Honda are customers in the very early phases of rolling out their EVs and that will scale up in the quarters and years ahead
  6. Stellantis and Scania will come after that, and at least one other German OEM after that.
  7. The move to EV’s is a secular trend and has only had a minor hiccup in terms of growth in some markets, caused by high interest rates.
  8. The move to EVs away from ICE is underpinned by widespread regulations in both the US and EU, which will force the change to EV’s.
  9. Interest rates are coming down in the US adn EU, which will cause big ticket purchases to return to an upward trend

-wsm.
(long ASPN 8%).

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@wsm007 this has to best description out there of what’s happening with ASPN. Nice job! In this past week I added back significant allocation to ASPN. And I may add more on continued share price weakness prior to this upcoming earnings release (on or around 30Oct).

GauchoRico

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All pouch and prismatic cell batteries, right? Not cylindrical. This seems the #1 key to me. Will pouch / prismatic always be used (and always need Pyrothin)? If not, ASPN might have a good quarter or two, or even see a nice bump when they guide for 2025, but long term it will always be a question of just how much hay they can make while the sun shines on them.

But maybe pouch and prismatic cell types are here to stay? Obviously if they’re just as good (cost effective even taking Pyrothin cost into account, etc) as cylinder, inertia might be enough to keep them around. But which of the 3 modalities is best? Or will something even better come along?

Great post @wsm007 – got me thinking about this company again! Just going through my process and considering what things are key to the thesis and potential risks.

Bear

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There was a great interview with the cfo at the Barclays 38th Annual CEO Energy & Power Conference on 4 September which answers a lot of the more detailed questions about how the tech works and why is it unique and differentiated vs alternatives.

https://event.webcasts.com/starthere.jsp?ei=1687712&tp_key=fa0c188ad3&language=en-us

This was the q&a about Tesla and cylindrical cells specifically:

Q: And I’m sure people are probably wondering of Tesla. Tesla is not customer because of their cylindrical batteries, right? So what are – how do they handle thermal runway?

A: They sort of don’t. If a cell in a Tesla like goes into thermal runaway, the car will burn to the ground. The way they handle it is, I think they’re relatively conservative in terms of how they use the cells and how they charge them. And if you take a Tesla Model Y, theoretically, it should deliver you 400 miles of range. But you see about 310 advertised. And in the real world, you probably get about 270 miles. And so that’s how they do it, right? The way people try to manage for thermal runaway in these cells is there’s theoretical models of how the cells are supposed to behave and they just kind of charge this, charge them and use them on the fringes of it. And so I told my wife when she charges her EV, she thinks it’s at 100%. It’s not really at 100%, it’s probably at about 80%. And when she’s discharging it down to 0, it’s not really 0, it’s probably closer to 30%.

I recommend reading the whole thing. It’s available for free on the Quartr app here: https://qcast.page.link/LAnPrYAGeNZJsY55A

-wsm

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I was wondering about this the last time I looked into Aspen where it seemed like Tesla’s solution is maybe 1/100th as effective as PyroThin. There used to be a site which was tracking Tesla fires although they stopped updating in February 2024,

Additionally, there’s a lot of stories from Helene about EVs catching fire,

Morelli’s crews fought three of them. St. Petersburg Fire Rescue reported at least two, one from an electric bike and another from a Mercedes-Benz EQB300 that led to what a fire department representative called “major damage to the home.” CNN and other outlets reported on a fire in Sarasota sparked by a Tesla Model X.

I’m highlighting that the story mentions a Mercedes and a Tesla which I don’t believe use the PyroThin.

What I am wondering is if there is a scenario where GM and Honda cars get a reputation that their cars do not catch fire and this causes Mercedes or Tesla to be forced to purchase from Aspen because their cars are noticeably unsafer.


Would be curious from the followers of Aspen how their Cryogel or the gel which protects against cold temperatures is doing. I know that’s a much lesser part of the story, but wondering if that product is still growing?

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Here is the portion of the text from the Barclay’s conference in Sept, where ASPN’s CFO was talking about the Engergy business. The bottom line is that he sees this business growing in the low double digits. I share the entire conversation though as I found the additional context helpful.

Speaker 1 is the Interviewer.
Speaker 2 is ASPN’s CFO, Ricardo Rodriguez.

Speaker 1: So maybe let’s just start off with the industrial energy business, and kind of where you started here. So maybe just kind of start initially, I think this is about 20 years ago. So initially kind of how did this develop and what was the initial applications for the aerogels?

Speaker 2: Yes. So the initial applications for aerogels were actually spacesuits with NASA. Again, on this quest to find a material that would provide a lot of thermal isolation with a very thin profile. And then as the team really honed in and developed the process, which is highly patented and proprietary to us. And it’s in essence taking a glass fiber substrate and impregnating it with a solution of, it’s in essence blended ethanol rock in ethanol and then creating the aerogel because anybody can make aerogel in the lab, but it would be a very brittle material.

Speaker 2: Think of it as an ice cube if you could take out the water. That’s what it would. And it’d be kind of useless because you wouldn’t be able to mold it around any shapes. It’d be so brittle and fragile that if you dropped it, it would just shatter. And so what the company pioneered is making it in a form that you can actually apply and wrap around pipes and cut into shapes and mold, etcetera, right?

Speaker 2: And that was the breakthrough. And so the 1st market that the company worked over a long time to build demand in was the energy, industrial insulation market. And if you get certified by the likes of an ExxonMobil or one of these large asset owners, then you only have to deal with 8 people to capture what can be a pretty large market. And that was the strategy that the team took. Right now, we have about $150,000,000 of supply to meet that demand in that end.

Speaker 2: But we over the past couple of years, we’ve seen demand really increase coming out of COVID as these asset owners think longer term around the value that everything that’s in these sites provides. And we believe that we have more demand in the energy business than what we can supply with our little $150,000,000 external manufacturing facility.

Speaker 1: So you’re putting basically, this is upgraded, much more efficient insulation on refining and petrochemicals. What are some of the other end markets that

Speaker 2: LNG facilities. We recently announced in our earnings call that we were in a carbon recapture project as well. And then there’s also a market of subsea pipe in pipe insulation. So if you think in the Nordics, the heavier this insulation is, the more the pipes can sag and it’s critical to keep the oil at lukewarm temperatures so it can flow through the subsea pipelines. And that’s a market that we pretty much had to ourselves here for the past 10 years.

Speaker 2: And as we’ve optimized our way to supply it and more recently, set up our operations so that we can supply that profitably, we’re now leaning more into those projects and they’re helping us get to the margins that we’ve had here recently.

Speaker 1: So you recently shifted a lot of all your manufacturing, I think just about all your manufacturing for this business from East Providence to China. Correct. Can you talk about kind of why you did that and some of the benefits you’ve seen so far?

Speaker 2: Yes. So I mean we have an amazing sales team that has been with the company in many cases from the beginning. And so when General Motors came and gave us the award to supply the Ultium battery platform with our earlier iterations of our cell to cell thermal barrier design, we knew that we were going to run out of aerogel supply at some point from Rhode Island. And it’s kind of insane, right? I mean, this company has spent 20 years building up demand in this energy industrial market.

Speaker 2: We’ve always believed that it could be a very profitable segment if the revenues were above $140,000,000 a year. And to have that get sun down simply because we can’t supply it because we’re ramping up the EV thermal barrier business was extremely painful. And so our Head of Sales on the Energy Industrial side along with the rest of the team started looking for alternate sources of supply at around the middle of 2023. And we went to China, had a bunch of conversations with folks that had assets that could potentially make the product. And it wasn’t until February of last year that the team could actually go to China to physically validate how
they were making all of the samples that were being shipped back and forth.

Speaker 2: And that’s when we saw that there was there were about 9 months of remaining work to do in order to validate them to the point that we could put our brands on their products and sell them as if they were ours. And then some initial test of the product, the feedback was very positive. So it’s actually less dusty than some of the stuff that we were producing in Rhode Island, given some changes in the formulation that our team made in order for that to work with the assets that the external manufacturing facility had. And it’s worked out very well. And this year, we’ve just continued to certify more and more of our 11 SKUs within that product line.

Speaker 2: And as I said, we’ll do over $150,000,000 of revenue this year, most of that being supplied by the external manufacturing facility.

Speaker 1: When do you anticipate reaching full capacity in China? And do you have opportunities to expand from there?

Speaker 2: I think here in Q4, we will very likely reach the maximum of the capacity that’s there. It’s no secret, it’s implied within our guidance that the Energy segment needs to do at least $42,000,000 of revenue per quarter here in the second half. And so, yes, we’re expecting that supply to be fully on for all SKUs, definitely in the Q4. And then there’s potential to increase our capacity further with some of the investments and the development that we’ve made there in Q3. We’ve had a brief shutdown that the team is managing here in Q3 to enable further supply.

Speaker 2: And our team also continues chasing additional demand. So we believe that business can grow in like the low double digits.

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I’ll pull out some specific quotes from that:

I’ve learned to discount automotive OEM promises, because they often don’t deliver. For instance, does anyone here recalls GM’s previous promise to have “30 new EVs by 2025”? That’s clearly not happening.

MotorTrend summed up the ER call those quotes are from with:

What a difference a year makes. General Motors spent the day telling investors that it has its act together when it comes to EVs and software, having weathered manufacturing hell, software snafus, and slowing demand.

And even when new models come out, there can be problems, as the Blazer EV rollout and stop-sale earlier this year showed.

I’m also not impressed by cherry-picked data. Looking at sequential, or even YoY data at best for me shows a turn-around from a pretty bad year for GM’s EVs.

But that second quarter was down from the first quarter:

Chevrolet delivered 11,217 EVs in Q2 (down 20% year-over-year)

Yes, it could be that GM isn’t just recovering from a bad EV sale spell (they discontinued the Bolt and new models weren’t ready in time, or had stop-sale almost immediately), and now they’re on an actual growth path. Even so, customer concentration remains a huge issue for ASPN, as Honda is only using it via GM’s Ultium packs and who knows what Honda will do for future models. And Toyota remains an intentional laggard for BEVs, with its current model bZ4X quite uncompetitive.

But, OK, let’s say GM is growing its EV sales well. Will they remain effectively ASPN’s only thermal barrier customer? What is Ford using instead of PyroThin? What about Mercedes, BMW, Audi, etc? Yeah, I know ASPN claims they have design wins and production programs, but we’re not seeing that in the numbers. Is this something about to happen later this year?

And with these other companies not really using PyroThin, how can you be so sure the new non-Ultium battery packs GM will design will also use PyroThin? GM and Aspen Aerogel actually collaborated for years on this design/product specifically for Ultium. So, I think future use in non-Ultium packs remains a question.

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You can’t group all Tesla battery packs together, since different models use different chemistries. The “standard range” models typically use LFP batteries, which are normally charged to 100%. The performance/range oriented models are normally charged to less, not because of thermal runaway concerns, but because of battery lifetime concerns.

The comment about getting 270 miles instead 310 has nothing to do with fire safety, but just how one drives versus EPA estimates. Why bring that un-related information into the discussion? To me, it’s just ASPN trying to denigrate Tesla unnecessarily.

And I don’t see any basis for claiming that the battery capacity of the Model Y Long Range is greater than the 75kwh specced. At that size, a 310 mile range is 242 watt-hours per mile, which is quite good.

A year and half ago, there was a rumor that GM was looking towards replacing Ultium with cylindrical cells. Most discounted it at the time, but with the recent termination of Ultium, that appears to have been true.

From GM’s Ultium battery gets the ultimatum - The Verge :thinking:

GM is also reducing the number of modules in its pack by up to 75 percent by using new prismatic cells, while higher-end cylindrical cells will be relegated to “performance” vehicles, [GM’s VP of Batteries] Kelty said.

But, the main change appears to be towards LFP batteries:

GM announced plans to adopt lithium iron phosphate (LFP) battery technology in order to decrease the cost of its EVs by “up to $6,000.” GM uses the more common nickel cobalt manganese (NCM) batteries in its Ultium platform.

Some automakers are using LFP-based cells already, including Tesla and Ford. There’s less complexity in LFP, they cost less to produce, and they aren’t dependent on the excessive cobalt used in NCM batteries. Cobalt has a bad rep as the “blood diamond of batteries,” and many automakers are trying to avoid it in the long term.

So again, with new chemistries and different style (prismatic, cylindrical cell) cells, I think it remains an open question how much, if any, Pyrothin will be used in GM future, non-Ultium, battery packs.

But, I feel we are all guessing at this point.

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I dunno @Smorgasbord1. How is this GM not growing EV sales? What am I cherry-picking?

Quarterly BEV deliveries:

Source: GM feeling bullish on BEVs

But yes, the growth will likely not be as big for ASPN in the upcoming Q as this last Q. But then it probably doesn’t need to be, as consensus analyst estimates have Q3 revenue and eps declining sequentially.

Anyhow, I think ‘nuf said from me. I’m placing my bets on them exceeding expectations. Let’s see where the Q ends.

-wsm.

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Thanks for finding that chart - I’d been looking but couldn’t find anything later than Q2. Granted, it does look like GM may have finally turned around EV sales. Although that chart doesn’t match up with the data I quoted earlier about Q2 being lower than Q1 - I wonder if there’s some US/Global disconnect happening in the data?

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Can moving manufacturing from East Providence to China be an issue if the trade wars get worse? Or qualifying for EV rebates from the US govt if even one part is from outside the US?

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