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AI infrastructure startup Crusoe has always differentiated itself from its competitors by finding creative ways to tap energy. Now, it’s investing in two of the most potentially transformative battery technologies on the market.
Crusoe has signed a deal with Form Energy to purchase 120 megawatts of iron-air batteries, which would store a massive 12 gigawatt-hours of electricity. Form promises that this novel type of battery — the first commercial installation is still under construction — will make renewable energy available for days on end, a crucial breakthrough for cleaning up the grid but also for cleanly powering data center operations. The deal comes just a month after Form won a 30-gigawatt-hour contract to supply a Google data center in Minnesota with round-the-clock clean energy.
Crusoe also said Tuesday it was doubling down on used electric vehicle batteries as a tool for cheaply storing electricity for computing.
Last summer, the company installed four modular data centers on the Nevada campus of battery recycling startup Redwood Materials; the latter built a field of solar panels and wired up an array of EV battery packs to serve round-the-clock clean power to Crusoe. After about nine months of operations, Crusoe decided to add 20 more of its modular Spark data centers to the site, utilizing the existing microgrid for a lot more computing. And Redwood said Wednesday it had passed key safety tests for its used-battery architecture, clearing the way for broader deployment.
The two announcements, emerging from the bustling CERAWeek energy conference in Houston, signal how one of the nation’s leading energy-savvy data center developers is scouting futuristic clean energy tech to speed the AI buildout today.
Crusoe launched in 2018 as a bitcoin miner that leveraged stranded energy resources, like oil-field gas that would have been flared. Its founders designed rugged computing modules that could survive in harsh circumstances, and built up domestic supply chains to give them more certainty on timing and delivery. Later, they flipped that expertise into the emerging AI infrastructure market.
Then, Crusoe shot to an improbable level of prominence for a startup of its size (it closed a $600 million fundraise in late 2024, valuing the company at $2.8 billion). Oracle chose Crusoe in 2025 to build the largest and most famous data center project to date: the Stargate flagship in Abilene, Texas. Stargate is typically described as a $500 billion effort, though that number actually refers to the broader joint venture between AI juggernaut OpenAI, cloud provider Oracle, and Japanese investment firm SoftBank. Crusoe has delivered two buildings in Abilene, which each consume about 100 megawatts to run their GPUs.
Setting aside the lingering questions around how much of the $500 billion investment pledge actually gets spent, it’s clear that Crusoe has leaped to the upper echelon of the AI industry. That means its choices to embrace novel clean energy technologies could turbocharge their pace of deployment and inspire new customers to follow suit.
The Form deal is a confident first bite. The purchase of 12 gigawatt-hours represents more storage capacity than any existing battery plant on the grid. To be clear, the deal does not imply that all that capacity will go to one site (and there’s no indication that iron-air batteries will go to Abilene in particular).
“They have a lot of projects that they’re working on simultaneously,” Form CEO Mateo Jaramillo told Canary Media. “They can choose where these first installations happen.”
The deal reserves iron-air batteries that will be manufactured in Weirton, West Virginia, and sets terms for the eventual purchase, Jaramillo said. Form is expanding its production capacity from 15 megawatts to 50 megawatts in a few months and will start initial deliveries of Crusoe’s 120 megawatts in 2027. At this point, Form has sold out its production through 2028 and is focused on executing the factory expansion, Jaramillo said.
Form chose iron as its key battery ingredient because it’s so cheap, which makes it economically viable to store and release clean energy over much longer time horizons than the four or five hours that today’s lithium-ion batteries are designed for. This means that a data center could rely on cheap wind and solar power, but call on Form’s tech to ensure on-demand electricity through multiday bouts of bad weather.
That serves Crusoe’s goal of bringing its own capacity as it builds data centers. Doing so avoids having to wait around for lengthy grid upgrades, and portends better community relations than having data centers compete with everyone else for existing power supplies.
Like Form, Redwood is working to deliver batteries with many more hours of storage, and at a radically lower price, than today’s lithium-ion batteries. Redwood does this not through breakthroughs in electrochemistry but by repurposing battery packs that would otherwise be dismantled.
Redwood’s original system looked like the product of creative tinkering — a field full of oddly shaped packs propped up on cinder blocks, quite unlike the uniform metal containers at most grid battery plants. Since then, it has formalized the architecture. Metal racks have replaced the cinder blocks, for instance, and the packs are mounted vertically so that more fit in a given space.
For performance, the company noted that its solar-battery microgrid has operated 99.2% of the time since installation. That’s commendable for a microgrid powered only by solar panels, but not up to the usual standards for AI computing. A spokesperson for Crusoe noted the data centers at Redwood’s campus tapped grid power as backup to maintain 99.9% uptime.
For the business to grow, Redwood founder JB Straubel (formerly CTO at Tesla, where Jaramillo once helmed the energy storage business) also needed to prove that the system wouldn’t catch fire. Just this month, Redwood cleared a barrage of safety tests by UL Solutions, the renowned independent safety lab. The repurposed batteries prevented the spread of fire from pack to pack, said Andrew Hoover, who leads product safety and compliance for Redwood. The Redwood team also ran a high-octane “deflagration” test by injecting explosive gases into a pack and igniting them. In this “absolute worst-case” scenario, Hoover noted, “the pack safely vented those gases out.”
Redwood’s battery installations buck the industry convention of stuffing batteries in a big metal container. But that decision makes the systems “inherently safe without relying on all these complex mitigation systems,” Hoover said. There’s no big box for explosive gas to build up in, and the packs are spread out enough to isolate any fire that might start.
With this safety credential to assuage potential customer concerns, Redwood is in a position to ship beyond its own campus in Nevada. Crusoe has plenty of other data center developments in need of power, and its latest storage deals expand its energy arsenal.
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