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UNITED STATES
SECURITIES AND EXCHANGE COMMISSION

WASHINGTON, D.C. 20549


FORM 10-K

x ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934

FOR THE FISCAL YEAR ENDED DECEMBER 31, 2003

OR

o TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934

For the transition period from ________ to ________.

COMMISSION FILE NUMBER 000-31687

EVERGREEN SOLAR, INC.

(Exact name of registrant as specified in its charter)
     
DELAWARE   04-3242254
(State or other jurisdiction of   (I.R.S. Employer
incorporation or organization)   Identification No.)
     
259 CEDAR HILL STREET   01752
MARLBORO, MASSACHUSETTS   (Zip Code)
(Address of principal executive offices)    

Registrant’s telephone number, including area code: 508-357-2221

Securities registered pursuant to Section 12(b) of the Act: NONE

Securities registered pursuant to Section 12(g) of the Act: COMMON STOCK, PAR VALUE $.01 PER SHARE

     Indicate by check mark whether the registrant (1) has filed all reports required to be filed by Section 13 or 15(d) of the Securities Exchange Act of 1934 during the preceding 12 months (or for such shorter period that the registrant was required to file such reports), and (2) has been subject to such filing requirements for the past 90 days:

     Yes x No o

     Indicate by check mark if disclosure of delinquent filers pursuant to Item 405 of Regulation S-K is not contained herein, and will not be contained, to the best of the registrant’s knowledge, in definitive proxy or information statements incorporated by reference in Part III of this Form 10-K or any amendment to this Form 10-K. o

     Indicate by check mark whether the registrant is an accelerated filer (as defined in Exchange Act Rule 12b-2).

     Yes o No x

     As of March 17, 2004, there were 16,086,604 shares of the registrant’s Common Stock, $.01 par value per share, outstanding. The aggregate market value of the registrant’s voting equity held by non-affiliates as of June 30, 2003 was approximately $15 million.

DOCUMENTS INCORPORATED BY REFERENCE

The registrant intends to file a definitive proxy statement pursuant to Regulation 14A within 120 days of the end of the fiscal year ended December 31, 2003. Portions of such proxy statement are incorporated by reference into Part III of this Annual Report on Form 10-K.



 


TABLE OF CONTENTS

PART I
ITEM 1. BUSINESS
ITEM 2. PROPERTIES
ITEM 3. LEGAL PROCEEDINGS
ITEM 4. SUBMISSION OF MATTERS TO A VOTE OF SECURITY HOLDERS
PART II
ITEM 5. MARKET FOR THE COMPANY’S COMMON EQUITY AND RELATED STOCKHOLDER MATTERS
ITEM 6. SELECTED FINANCIAL DATA
ITEM 7. MANAGEMENT’S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND RESULTS OF OPERATIONS
ITEM 7A. QUANTITATIVE AND QUALITATIVE DISCLOSURES ABOUT MARKET RISK
ITEM 8. FINANCIAL STATEMENTS AND SUPPLEMENTARY DATA
ITEM 9. CHANGES IN AND DISAGREEMENTS WITH ACCOUNTANTS ON ACCOUNTING AND FINANCIAL DISCLOSURE
ITEM 9A. Controls and Procedures
PART III
ITEM 10. DIRECTORS AND EXECUTIVE OFFICERS OF THE REGISTRANT
ITEM 11. EXECUTIVE COMPENSATION
ITEM 12. SECURITY OWNERSHIP OF CERTAIN BENEFICIAL OWNERS AND MANAGEMENT
ITEM 13. CERTAIN RELATIONSHIPS AND RELATED TRANSACTIONS
ITEM 14. PRINCIPAL ACCOUNTING FEES AND SERVICES
ITEM 15. EXHIBITS, FINANCIAL STATEMENT SCHEDULES AND REPORTS ON FORM 8-K
REPORT OF INDEPENDENT AUDITORS
CONSOLIDATED BALANCE SHEETS AS OF DECEMBER 31, 2002 AND 2003
CONSOLIDATED STATEMENTS OF OPERATIONS
CONSOLIDATED STATEMENTS OF STOCKHOLDERS’ EQUITY
CONSOLIDATED STATEMENTS OF CASH FLOWS
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS
SIGNATURES
Ex-21.1 Subsidiaries
Ex-23.1 Consent of PricewaterhouseCoopers LLP
Ex-31.1 Certification of CEO
Ex-31.2 Certification of CFO
Ex-32.1 Certification of CEO - Section 906
Ex-32.2 Certification of CFO - Section 906


Table of Contents

PART I

ITEM 1. BUSINESS:

OVERVIEW

     We develop, manufacture and market solar power products that are capable of providing reliable and environmentally clean electric power throughout the world. Our solar power products are targeted at the global solar power market. We believe our proprietary and patented solar power technologies, based on our String RibbonTM technology, offer significant design, cost and manufacturing advantages over competing solar power technologies. We intend to become a leading producer of high-quality solar power products by expanding our manufacturing capacity, reducing our manufacturing costs, developing innovative solar power products, increasing our distribution capabilities and pursuing strategic relationships.

     Since our formation in 1994, we have conducted research and development of advanced process and product technologies and, between 1997 and June 2001, we used pilot manufacturing facilities to refine our solar power products and manufacturing processes. Also in 1997, we began shipping small quantities of commercial products. In 2001, we expanded our manufacturing capacity capability by relocating our operations to a 56,250 square foot facility in Marlboro, Massachusetts where we constructed a new manufacturing line. We are continuing to refine, develop and commercialize a number of laboratory-demonstrated advancements in our solar power technologies, including advanced String Ribbon crystal growth, more efficient solar cells and improved solar panel designs. Since our inception, we have shipped over 50,000 solar panels for residential, commercial and industrial applications in the United States and internationally. As we continue to increase production volumes, we intend to actively expand existing and seek new distribution and marketing arrangements.

FINANCING TRANSACTION

     On May 15, 2003, the Company consummated the transaction contemplated by a Stock and Warrant Purchase Agreement which was entered into on March 21, 2003 with Perseus 2000, L.L.C., Nth Power Technologies Fund II, LP, Nth Power Technologies Fund II-A, LP, RockPort Capital Partners, L.P., RP Co-Investment Fund, I, Micro-Generation Technology Fund, LLC, UVCC Fund II, UVCC II Parallel Fund, L.P., Caisse de depot et placement du Quebec, CDP Capital — Technology Ventures U.S. Fund 2002 L.P., Beacon Power Corporation, Massachusetts Technology Park Corporation, Zero Stage Capital VII, L.P., Zero Stage Capital (Cayman) VII, L.P., Zero Stage Capital SBIC VII, L.P., IMPAX Environmental Markets plc, Merrill Lynch New Energy Technology Plc, MLIIF New Energy Fund, PNE Invest Limited, Odyssey Fund, SAM Private Equity Energy Fund LP, SAM Sustainability Private Equity LP and SAM Smart Energy. As a result of the consummation of this transaction, the Company issued 26,227,668 shares of Series A convertible preferred stock at a per share purchase price of $1.12. Additionally, Beacon Power Corporation purchased a warrant to purchase 2,400,000 shares of common stock at a per share exercise price equal to $3.37, for $100,000. A total of $29.5 million was raised as a result of the consummation of the transaction. The proceeds to the Company, net of financing expenses of approximately $849,000, were approximately $28.6 million for the transaction. The shares of Series A convertible preferred stock were initially convertible into shares of common stock on a 1-to-1 basis which is subject to adjustment to account for the payment of dividends, to take into account certain changes to the Company’s capital structure and to account for future dilutive issuances. As a condition to the obligation of the purchasers to consummate the financing transaction, the Company registered for resale the shares of common stock issuable upon the conversion of the Series A convertible preferred stock and the exercise of the warrant.

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HISTORICAL MILESTONES

     We were incorporated in August 1994 and, to date, we have achieved the following milestones along our product development and commercialization schedule:

             
Date           Historical Milestone
 
October
    1994     Evergreen Solar founded with four employees in a 2,500 square foot laboratory.
October
    1995     First String Ribbon wafers produced.
April
    1997     9,400 square foot pilot manufacturing facility operational.
October
    1997     First commercial sale of solar panels produced using String Ribbon technology.
June
    1999     Total sales of solar panels of 2,500 units and 100 kilowatts achieved.
December
    1999     Kawasaki investment of $5 million and execution of a strategic distribution and marketing agreement.
March
    2000     Leased 56,250 square foot manufacturing and headquarters facility located in Marlboro, Massachusetts.
August
    2000     Renovation of our Marlboro manufacturing facility and headquarters begun.
June
    2001     First shipment of solar panels from our new Marlboro manufacturing facility.
November
    2001     New distribution relationships in the U.S. and Europe.
December
    2001     Shipment of our 10,000th solar panel.
June
    2002     Achieved first quarterly $1.0 million in product sales.
December
    2002     Demonstration of double ribbon growth to boost productivity.
December
    2002     Solar system installed on White House.
May
    2003     Close of $29.5 million preferred stock and warrant financing transaction
Dec
    2003     Richard M. Feldt appointed as new Chief Executive Officer
Jan
    2004     Shipment of our 50,000th solar panel
Jan
    2004     Demonstrated quad-ribbon growth process

INDUSTRY BACKGROUND

     The electric power industry is one of the world’s largest industries. Furthermore, electricity accounts for a growing share of overall energy use. We believe that deregulation and technological innovations are creating significant opportunities for new entrants and technologies within the electric power industry, just as these changes have created similar opportunities in other regulated industries such as telecommunications, banking and transportation.

     We believe that distributed generation is one of the most promising areas for growth in the global electric power industry. Distributed generation is defined as point-of-use electricity generation that either supplements or bypasses the electric utility grid, and employs technologies such as solar power, microturbines and fuel cells. Distributed generation is expected to provide greater portability, reliability, power quality and user control. We believe capacity constraints, increased demand for power reliability and quality, and new environmental initiatives will drive the demand for distributed generation.

     We further believe that environmentally benign, locally sourced power generation will become increasingly more important for economic development, environmental policy, and national security. Increasing attention to global warming, global energy policy, and regional stability and development will support the deployment of distributed generation, particularly renewable energy.

SOLAR POWER APPLICATIONS AND BENEFITS

     Unlike many other distributed generation technologies that have been under development but not in widespread commercial use, solar power technology has had a growing worldwide market for over 25 years in the following applications:

-   On-grid. On-grid applications provide supplemental electricity to customers that are served by an electric utility grid but choose to generate a portion of their electricity needs on-site. On-grid applications have been the fastest growing part of the solar power market, largely driven by the worldwide trend toward deregulation and privatization of the electric power industry as well as by government initiatives, including incentive programs to subsidize and promote solar power systems in several countries including Japan, Germany and the United States. On-grid applications include residential and commercial rooftops and building facades and are available for both new construction and existing structures.

-   Off-grid. Off-grid applications serve markets where access to conventional electric power is not economical or physically feasible. Solar power products can provide a cost-competitive, reliable alternative for powering highway call

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    boxes, microwave stations, portable highway road signs, remote street or billboard lights, vacation homes, rural homes in developed and developing countries, water pumps and battery chargers for recreational vehicles and other consumer applications.

     Solar power has emerged as one of the primary distributed generation technologies seeking to capitalize on the opportunities resulting from trends affecting the electric power industry. Relative to other distributed generation technologies, solar power benefits include:

-   Modular and scaleable. From tiny solar cells powering a hand-held calculator to an array of roof panels powering an entire home to acres of panels on a commercial building roof or field, solar power products can be deployed in many sizes and configurations and can be installed almost anywhere in the world. Solar is among the best technologies for power generation in urban areas, environmentally sensitive areas, and geographically remote areas in both developing and developed countries.

-   Reliable. With no moving parts and no fuel supply required, solar power systems reliably power some of the world’s most sensitive applications, from space satellites to microwave stations in the mountains and other remote, harsh environments which typically require reliable power sources. Solar panels typically carry warranties as long as 25 years.

-   Dual use. Solar panels are expected to increasingly serve as both a power generator and the skin of the building. Like architectural glass, solar panels can be installed on the roofs or facades of residential and commercial buildings.

-   Environmentally cleaner. Solar power systems consume no fuel and produce no air or water emissions.

THE SOLAR POWER CHALLENGE

     Although solar power has been technically proven for over 25 years and is widely cost-effective for off-grid applications, we believe the principal challenge to widespread adoption of solar power is reducing manufacturing costs without impairing product performance or reliability. We believe the following advancements in solar power technology are necessary to meet this challenge:

-   Efficient material use. Reduce raw materials waste, particularly the waste associated with slicing silicon blocks by conventional crystalline silicon technology.

-   Simplified and continuous processing. Reduce reliance on expensive, multi-step manufacturing processes.

-   Improved product design and performance. Increase product conversion efficiency, longevity and ease of use. Conversion efficiency refers to the fraction of the sun’s energy converted to electricity.

     We further believe the two principal solar power technologies, crystalline silicon and thin films, have not adequately addressed this challenge:

     Crystalline Silicon. Crystalline silicon technology was the earliest practiced solar power technology and remains the foundation for most solar power applications. Conventional crystalline silicon technology involves slicing thin wafers from solid crystalline silicon blocks. Crystalline silicon products are known for their reliability, performance and longevity; however, factors such as high materials waste from slicing, and multi-step processing procedures have limited the ability of conventional crystalline silicon manufacturers to reduce manufacturing costs.

     Thin Films. While most major solar power manufacturers currently rely on crystalline silicon technology for the majority of their solar cell production, many are also developing alternative thin film technologies to achieve lower manufacturing costs. Thin film technology involves depositing several thin layers of silicon or more complex materials on a substrate to make a solar cell. Although thin film techniques may be able to use material more efficiently than conventional crystalline silicon, we believe the commercial acceptance of thin film technology is limited due to higher capital costs, lower manufacturing yields, lower conversion efficiency, reduced product performance and reliability, and, in some cases, concerns with toxic materials. Recent curtailments of R&D programs as well as plant closures by some industry participants, most notably BP Solar in 2002, highlight the commercial challenges that thin films have faced.

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OUR TECHNOLOGY SOLUTION

     We believe our technologies and processes are unique among our competitors. Both our technologies and processes have been designed to reduce manufacturing costs while improving product design. We are developing technology at the wafer, cell and panel stages of manufacturing, and we hold patents and other intellectual property in all three areas. We believe our String Ribbon wafer manufacturing technology is our core technology and offers a substantial opportunity to reduce cost and otherwise advance our business through reduced materials cost, simpler processing and lower required economies of scale.

     In the String Ribbon technique, strings are pulled vertically through a shallow pool of molten silicon, and the silicon solidifies between the strings to form a continuous ribbon of crystalline silicon. The ribbon is then cut and prepared for cell fabrication. The use of strings to aid in the simplified growth of a silicon ribbon is what distinguishes our proprietary and patented String Ribbon technology from other advanced crystalline silicon wafer technologies that do not involve slicing. We believe our String Ribbon technology for the growth of solar wafers has the following significant advantages:

-   Efficient materials use. Unlike conventional bulk crystalline silicon wafer technology, in which solid blocks of silicon are sliced into thin wafers at significant expense and silicon waste, our technology grows a continuous, flat ribbon to the desired thickness. Since our technology does not involve slicing solid blocks, we can use approximately half as much silicon as conventional crystalline silicon techniques and we believe we can reduce this amount to about one-fifth in the future through production of thinner wafers.

-   Continuous processing. Our technology permits the continuous growth of crystalline silicon ribbon, which can lead to high automation, efficient equipment use and improved productivity.

-   Modularity. Dual-String Ribbon furnaces individually have a capacity of approximately 0.1 megawatts per year, whereas conventional bulk technology typically has an individual machine capability of 3 or more megawatts per year, and the trend has been to increase minimum unit size in recent years. We expect that this modularity may enable us to achieve economies of scale at a smaller scale than conventional technologies, which could enable us to manufacture internationally in more numerous, smaller factories to better serve global markets.

OUR PRODUCTS

     Solar power products in general are built-up through four stages of production:

-   Wafers. A crystalline silicon wafer is a flat piece of crystalline silicon that can be processed into a solar cell. Our rectangular wafers currently measure 81 millimeters by 150 millimeters and are approximately as thick as a business card.

-   Cells. A solar cell is a device made from a wafer that converts sunlight into electricity by means of a process known as the photovoltaic effect. Our solar cells produce approximately 1.5 watts of power each.

-   Panels. A solar panel is an assembly of solar cells that have been electrically interconnected and laminated in a physically durable and weather-tight package. A typical solar panel can produce from 20 to 200 watts of power and range in size from two to 15 square feet. A 100-watt solar panel can power a standard 100-watt light bulb, or approximately 3% of the power requirements of a typical home in the United States. Our current solar panels range from 47 to 115 watts in power.

-   Systems. A solar system is an assembly of one or more solar panels that have been physically mounted and electrically interconnected, often with batteries and/or power electronics, to produce electricity. Typical residential on-grid systems contain between 10-40 panels and produce 1-4 kW.

     We sell primarily solar panels, although we may in the future also sell wafers, cells, or systems. We believe our panels are competitive with other products in the marketplace, and some customers have commented that our panels have benefits regarding appearance, electrical design capability, and ease of use.

     Our solar panels are certified to international standards for safety and quality. If our development programs are successful, we expect to continue to increase the conversion efficiency and power of our solar panels as we expand our manufacturing capacity.

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SALES AND MARKETING

     Market Focus

     We intend to primarily target the on-grid markets and the off-grid rural electrification market, where we believe growth prospects are the largest and where we expect our solar power technology will provide us the greatest competitive advantage. These markets are characterized as follows:

-   On-grid. The on-grid market is currently the fastest growing solar power market within which we are focused primarily on U.S. and European markets.

-   Off-grid rural electrification. Within the off-grid market, we believe that rural electrification has the largest potential but is the least penetrated market as evidenced by the two billion people in the world without conventional electricity. Marketing, financing, local infrastructure and support are projected to remain the principal challenges to greater expansion of this market. To date, we have primarily pursued sales in Central and South America and the Pacific Rim.

     Since inception, over 89% of our product sales have been to on-grid market segments, and over 65% of our product sales have been exported from the U.S. The majority of our export sales to date have been to Europe.

     Distribution, Marketing and Other Strategic Relationships

     We bring our solar power products to market using distributors, system integrators and other value-added resellers. Our resellers often add value through system design by incorporating our panels with batteries, associated electronics, structures and wiring systems. Most of our resellers have a geographic or applications focus. Our channel partners include companies that are exclusively solar distributors as well as others for whom solar power is an extension of their core business, such as, engineering design firms or other energy product marketers.

     We expect to collaborate closely with a relatively small number of resellers throughout the world. We currently have approximately 25 distributors worldwide and are actively adding new accounts and channel partners. We intend to selectively pursue additional strategic relationships with other companies worldwide for the joint marketing, distribution and manufacturing of our products. These resellers are expected to range from large, multinational corporations to small, development-stage companies, each chosen for their particular expertise. We believe that these relationships will enable us to leverage the marketing, manufacturing and distribution capabilities of other companies, explore opportunities for additional product development, and more easily and cost-effectively enter new geographic markets, attract new customers and develop advanced solar power applications.

     We currently work with a relatively small number of resellers who have particular expertise in a selected geographic or applications market segment. Sales to our ten largest resellers have accounted for approximately 82% of our total product revenues since inception. No single reseller has accounted for more than 45% of total revenues over that period. As we continue to expand manufacturing capacity and sales volumes, we anticipate developing relationships with additional resellers. During fiscal year 2003, approximately 27% of our product sales were made to resellers in the United States, and all of our research revenue was generated within the United States. During the same period, revenue from a German distributor and the National Renewable Energy Laboratory accounted for approximately 39% and 10% of total revenues, respectively.

     In addition, we market our products through trade shows, on-going customer communications, promotional material, our web site, direct mail and advertising. Our staff provides customer service and applications engineering support to our distribution partners while also gathering information on current product performance and future product requirements. Our internal sales force currently handles all solar power product sales.

MANUFACTURING

     Our principal manufacturing objective is to provide for large-scale manufacturing of our solar power products at low costs that will enable us to penetrate price-sensitive solar power markets. Our 56,250 square foot facility in Marlboro, Massachusetts includes approximately 35,000 square feet of manufacturing space. This facility includes a complete line of equipment to manufacture String Ribbon wafers, fabricate and test solar cells, and laminate and test panels. The first of the facility’s two planned manufacturing lines entered service in 2001. During 2002, we initiated the design and construction of the second production line in our Marlboro facility. At the end of 2003, equipment for parts of the cell processing and module fabrication operations began production.

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     In addition to our current investment in our Marlboro, Massachusetts facility, we intend to selectively pursue opportunities to establish local manufacturing arrangements on a worldwide basis. Because the market opportunity for solar power encompasses numerous applications in both developed and developing nations worldwide, we expect a significant portion of our future sales will be made outside of the United States. Despite these opportunities, manufacturing of solar power products has remained largely concentrated in the United States, Europe and Japan due to factors such as reduced economies of scale and technical process complexities of establishing local manufacturing facilities.

     In spite of these barriers, we believe there are several advantages to local manufacturing, including enhanced brand recognition in local markets, avoidance of import tariffs and access to local private or public sector financing. We believe that our String Ribbon technology and our innovative manufacturing techniques offer greater advantages than other competing technologies, which we believe will enable us to establish fully integrated factories at a smaller scale that can better grow in concert with market demands. Consequently, we expect to pursue local manufacturing of our products in selected target markets. We also expect that our technologies will allow us to efficiently scale our production to take advantage of market opportunities as they arise.

RESEARCH AND DEVELOPMENT

     Because we believe continuously improving our technology is an important part of our overall strategy, we have maintained and intend to maintain a strong research and development effort. To this end, our Marlboro, Massachusetts facility has approximately 6,000 square feet dedicated to research and development and contains equipment to support the development, fabrication and evaluation of new solar power products and technologies.

     We intend to continue our policy of selectively pursuing contract research, product development and market development programs funded by various agencies of the United States, state and international governments to complement and enhance our own resources. The percentage of our total revenues derived from government-related contracts was approximately 17% for the year ended December 31, 2003. During 2003, we had two active multi-year research contracts summarized as follows (in millions):

                 
    National Institute    
    of Standards and   National Renewable
    Technology
  Energy Laboratory
Total government funding
  $ 2.0     $ 3.0  
Total funding authorized as of December 31, 2003
  $ 2.0     $ 2.0  
Revenue recorded through December 31, 2003
  $ 2.0     $ 1.6  
Remaining revenue to be recorded
  $ 0.0     $ 1.4  
Expiration date
  October 31, 2003   May 31, 2005

     We have fully recognized all revenue associated with our contract with the National Institute of Standards and Technology which expired on October 31, 2003, and we expect the remaining $1.4 million of revenue associated with the contract with the National Renewable Energy Laboratory will be recognized as work is performed over the remaining life of the contract, which expires on May 31, 2005.

     These and other research contracts we have obtained generally provide for development of advanced materials and methods for wafer, cell and panel manufacturing, product development and market development. In all cases to date, we retain all rights to any intellectual property and technological developments resulting from the government funding, with the exception of government “march-in” rights to practice the technology on its own behalf and certain rights universities retain for work they perform under subcontract to us. These contracts usually require the submission by us of technical progress reports, most of which may become publicly available. These contracts are generally cost-shared between the funding agency and us with our share of the total contract cost historically ranging from approximately 30% to 70%. The contracts normally expire between six months and three years from their initiation. We recognized research revenues of $932,000 in 2001, $1.4 million in 2002, and $1.6 million in 2003 from several government-sponsored research contracts. We recorded research and development expenditures, including the cost of research revenue, of $3.1 million in 2001, $3.7 million in 2002 and $3.8 million in 2003.

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The following table summarizes research revenues received from various government agencies as a percentage of total revenues:

                         
    2001
  2002
  2003
National Institute of Standards and Technology
    24 %     11 %     7 %
National Renewable Energy Laboratory
    15 %     10 %     10 %
 
   
 
     
 
     
 
 
 
    39 %     21 %     17 %

INTELLECTUAL PROPERTY RIGHTS

  Patents

     We believe that our commercial success will significantly depend on our ability to protect our intellectual property rights underlying our proprietary technologies. We seek United States and international patent protection for major components of our technology platform, including our crystalline silicon wafers, solar cells and solar panels. We own or have licensed 20 issued United States patents and 3 issued foreign patents in the solar power field. These patents began to expire in 2003 and will all be expired by 2019. In addition, we have 5 United States patent applications pending. We decide whether and in what foreign countries to file counterparts of our United States patent applications. We devote substantial resources to building a strong patent position, and we intend to continue to file additional United States and foreign patent applications to seek protection for technology we deem important to our commercial success.

     Crystalline Silicon Wafers. Dr. Emanuel Sachs, a tenured Professor of Mechanical Engineering at the Massachusetts Institute of Technology, developed our core String Ribbon technology. Dr. Sachs has been awarded three issued United States patents for the String Ribbon technology. An additional issued patent for a related technology, invented by two employees of the United States National Renewable Energy Laboratory, formerly the Solar Energy Research Institute, was assigned to Dr. Sachs in 1984.

     In September 1994, Dr. Sachs granted us an irrevocable, worldwide, royalty-bearing license to practice the String Ribbon technology and related patents under a license and consulting agreement. The patents underlying this agreement began to expire in 2003 and will all have expired by the end of 2004. This agreement permits us to sublicense any of our license and other rights under the agreement. The license is exclusive worldwide, subject only to nonexclusive, nontransferable rights held by the United States Department of Energy to practice the String Ribbon technology on its own behalf. Dr. Sachs continues to actively consult with Evergreen Solar on new technological developments.

     We have been awarded 3 issued United States patents and have filed 6 patent applications on our own, internally-developed inventions related to String Ribbon and wafer fabrication, which are method inventions relating to automated, high-yield production techniques.

     Solar Cell Fabrication. We have been awarded 5 issued United States patents and 1 foreign patent relating to our solar cell processing technology. The issued United States patents relate to the method for forming wrap-around contacts on solar cells and a method for processing solar cells.

     Solar Panels. We have been awarded 8 issued United States patents and 1 foreign patent relating to advanced solar panel designs. The 8 issued United States patents relate to solar cell modules with an improved backskin, solar cell modules with an interface mounting system, an encapsulant material for solar cell modules and a solar cell roof tile system.

     The long-term status of patents in our industry, as well as others, are generally uncertain and involve complex legal and factual questions. Furthermore, even if patents are licensed or issued to us, others may design around the patented technologies. In addition, we could incur substantial costs in litigation if we are required to initiate patent litigation to enforce our patent rights, and the outcome of any patent litigation is uncertain. The following may impair our patent positions:

-   our pending patent applications may not result in issued patents;

-   the claims of patents which are issued may not provide meaningful protection;

-   we may not develop additional proprietary technologies that are patentable;

-   patents licensed or issued to us may not provide a basis for commercially viable products or may not provide us with competitive advantages and may be challenged by third parties; or

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-   patents of others may have an adverse effect on our ability to do business.

     Although we do not believe that our technologies infringe the rights of third parties, third parties could in the future assert infringement claims against us, which may result in costly litigation or require us to obtain a license to third-party intellectual property rights. We may be unable to obtain required licenses or obtain these licenses on terms that are acceptable to us, either of which would substantially impair our business.

     Trade Secrets and Other Rights

     With respect to proprietary know-how that is not patentable and for processes for which patents are difficult to enforce, we rely on trade secret protection and confidentiality agreements to protect our interests. We believe that several elements of our solar power products and manufacturing processes involve proprietary know-how, technology or data, which are not covered by patents or patent applications including selected materials, technical processes, equipment designs, algorithms and procedures. We have taken security measures to protect proprietary know-how and technologies and confidential data, and we continue to explore additional methods of protection. While we require all employees, key consultants and other third parties to enter into confidentiality agreements with us, we cannot be assured that proprietary information will not be disclosed inappropriately, that others will not independently develop substantially equivalent proprietary information and techniques or otherwise gain access to our trade secrets, or that we can meaningfully protect our trade secrets. Any material leak of confidential information into the public domain or to third parties could result in the loss of a competitive advantage in the solar power market.

COMPETITION

     The market for solar power products is intensely competitive. There are over 20 companies in the world that produce solar power products, including BP Solar, Kyocera Corporation, Royal Dutch Shell, Sharp Corporation, RWE, and Sanyo Corporation. All of these solar power product producers, as well as several others, have historically derived all or a majority of their solar power product sales from conventional manufacturing technology that involves using wafers made from slicing solid blocks of crystalline silicon. In addition, some of these companies are developing advanced crystalline silicon or thin film technologies, including technologies such as advanced crystalline sheet and ribbon technologies and thin films of amorphous silicon, cadmium telluride and copper indium diselenide, and project future cost savings similar to or greater than ours. We believe several of our competitors are developing and are currently producing products based on crystalline silicon wafer technologies that, like String Ribbon, do not involve slicing silicon blocks.

     We believe the technologies used in our current solar power products have some similarities with those employed in our competitors’ products. However, because our solar power products are made from crystalline silicon, we believe our current products may be more reliable than those made from thin film technologies which often use materials, such as amorphous silicon, which we believe may be less stable.

     Solar power has certain advantages and disadvantages when compared to other conventional energy sources. The advantages include the ability to deploy products in many sizes and configurations, to install products almost anywhere in the world, to provide reliable power for many applications, to serve as both a power generator and the skin of a building and to eliminate air, water and noise emissions. However, unlike most conventional energy generators, which can produce power on demand, solar power cannot generate power when sunlight is not available. In addition, based on current technology, the upfront cost, including installation, of conventional energy generators is often lower than that of solar power products. However, we believe that the relative cost of power produced over the lifetime of solar products as compared with conventional energy generators often depends on the application. For example, solar power products may be more cost-effective over the long-term for remote applications that are not connected to the utility grid and that have smaller power requirements, while conventional power sources may be more cost effective for larger, grid-connected applications.

     Many of our competitors have substantially greater financial resources, research and development staff, manufacturing facilities, sales and marketing experience, distribution channels and human resources than we do. In order to compete effectively against these companies, we will need to demonstrate to potential customers and partners that our solar power products perform better, or are less expensive than those of our competitors.

     In addition, we believe that the market for solar power specifically, and electric power in general, may be subject to rapid technological development. This rapid development may result in some of our solar power products becoming obsolete before we can recover development expenses. We also expect that future competition will come not only from existing competitors, but also from new entrants to the market with new technological solutions. We may be unable to compete successfully against

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present and future competitors and our failure to successfully compete could significantly reduce our market share, our revenues and our prospects for profitability.

ENVIRONMENTAL REGULATIONS

     We use, generate and discharge toxic, volatile or otherwise hazardous chemicals and wastes in our research and development and manufacturing activities. We are subject to a variety of federal, state and local governmental regulations related to the storage, use and disposal of hazardous materials.

     We believe that we have all environmental permits necessary to conduct our business. We believe that we have properly handled our hazardous materials and wastes and have not contributed to any contamination at any of our past or current premises. We are not aware of any environmental investigation, proceeding or action by federal or state agencies involving our past or current facilities. If we fail to comply with present or future environmental regulations, we could be subject to fines, suspension of production or a cessation of operations. Any failure by us to control the use of or to restrict adequately the discharge of hazardous substances could subject us to substantial financial liabilities, operational interruptions and adverse publicity, any of which could materially and adversely affect our business, results of operations and financial condition. In addition, under some federal and state statutes and regulations, a governmental agency may seek recovery and response costs from operators of property where releases of hazardous substances have occurred or are ongoing, even if the operator was not responsible for the release or otherwise was not at fault.

EMPLOYEES

     As of December 31, 2003, we had 151 full-time employees, including 18 engaged in research and development and 118 engaged in manufacturing. Nineteen of our employees have advanced degrees, including 5 with Ph.D.s. None of our employees are represented by any labor union nor are they organized under a collective bargaining agreement. We have never experienced a work stoppage and believe that our relations with our employees are good.

AVAILABLE INFORMATION

     Our annual report on Form 10-K, quarterly reports, current reports on Form 8-K, and all amendments to those reports are made available free of charge though our internet website (http://www.evergreensolar.com) as soon as practicable after such material is electronically filed with, or furnished to, the Securities and Exchange Commission.

ITEM 2. PROPERTIES:

     Our headquarters is currently located in a leased space in Marlboro, Massachusetts, where we currently occupy approximately 56,250 square feet of administrative, laboratory and manufacturing space. Our lease expires on June 30, 2010.

     On January 24, 2004, we signed a new lease for 23,839 square feet of additional warehouse and office space located in Marlboro, Massachusetts. This lease expires on January 24, 2010.

ITEM 3. LEGAL PROCEEDINGS:

     We are not a party to any material legal proceedings.

ITEM 4. SUBMISSION OF MATTERS TO A VOTE OF SECURITY HOLDERS:

     No matters were submitted to a vote of security holders during the quarter ended December 31, 2003.

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PART II

ITEM 5. MARKET FOR THE COMPANY’S COMMON EQUITY AND RELATED STOCKHOLDER MATTERS:

Market for Our Common Stock

     Our common stock is traded on the Nasdaq National Market under the symbol “ESLR”. The following table sets forth for the calendar periods indicated, the high and low sales price of our common stock on the Nasdaq National Market.

                 
    High
  Low
2002:
               
First Quarter
  $ 4.79     $ 2.06  
Second Quarter
  $ 3.48     $ 1.32  
Third Quarter
  $ 1.70     $ 0.65  
Fourth Quarter
  $ 1.68     $ 0.44  
2003:
               
First Quarter
  $ 2.32     $ 1.00  
Second Quarter
  $ 1.98     $ 1.26  
Third Quarter
  $ 3.25     $ 1.01  
Fourth Quarter
  $ 2.89     $ 1.48  

     On March 17, 2004 there were approximately 176 stockholders of record of our common stock. We have never declared or paid cash dividends on shares of our common stock. Holders of shares of Series A convertible preferred stock are entitled to a quarterly dividend at an annual rate of 10% payable in cash or, at our option, we may accrete the Series A convertible preferred stock 10% dividend to the conversion price and liquidation preference of the Series A convertible preferred stock. Apart from the dividend on the Series A convertible preferred stock, we intend to retain any earnings for use in our business.

     Please see Part III, Item 12: Securities Ownership of Certain Beneficial Owners and Management for the information regarding securities authorized for issuance under our equity compensation plans.

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ITEM 6. SELECTED FINANCIAL DATA:

     You should read the data set forth below in conjunction with our financial statements and related notes and “Management’s Discussion and Analysis of Financial Condition and Results of Operations” appearing elsewhere in this filing. The statement of operations data presented below for the fiscal years ended December 31, 2001, 2002, and 2003 and the balance sheet data at December 31, 2002 and 2003 have been derived from our audited financial statements which appear elsewhere in this filing. The statement of operations data presented below for the years ended December 31, 1999 and 2000, and the balance sheet data at December 31, 1999, 2000 and 2001 have been derived from our audited financial statements, which are not included in this filing.

                                         
    Year Ended December 31,
    1999
  2000
  2001
  2002
  2003
            (in thousands, except for per share data)        
STATEMENT OF OPERATIONS DATA:
                                       
Product revenues
  $ 189     $ 419     $ 1,546     $ 5,296     $ 7,746  
Research revenues
    2,113       1,753       932       1,448       1,565  
 
   
 
     
 
     
 
     
 
     
 
 
Total revenues
    2,302       2,172       2,478       6,744       9,311  
 
   
 
     
 
     
 
     
 
     
 
 
Operating Expenses:
                                       
Cost of product revenues
    997       2,795       9,649       12,405       15,379  
Research and development expenses, including cost of research revenues
    3,091       3,382       3,063       3,692       3,791  
Selling, general and administrative expenses
    1,309       2,505       4,088       4,520       5,337  
 
   
 
     
 
     
 
     
 
     
 
 
Total operating expenses
    5,397       8,682       16,800       20,617       24,507  
 
   
 
     
 
     
 
     
 
     
 
 
Operating loss
    (3,095 )     (6,510 )     (14,322 )     (13,873 )     (15,196 )
Net interest income
    163       1,305       1,845       674       222  
 
   
 
     
 
     
 
     
 
     
 
 
Net loss
    (2,932 )     (5,205 )     (12,477 )     (13,199 )     (14,974 )
Accretion and dividends on Series A convertible preferred stock
    (1,231 )     (2,283 )                 (13,498 )
 
   
 
     
 
     
 
     
 
     
 
 
Net loss attributable to common stockholders
  $ (4,163 )   $ (7,488 )   $ (12,477 )   $ (13,199 )   $ (28,472 )
 
   
 
     
 
     
 
     
 
     
 
 
Net loss per share attributable to common stockholders (basic and diluted)
  $ (5.18 )   $ (2.96 )   $ (1.10 )   $ (1.16 )   $ (2.39 )
Weighted average shares used in computing basic and diluted net loss per share attributable to common stockholders
    803       2,530       11,304       11,405       11,899  
                                         
    December 31,
    1999
  2000
  2001
  2002
  2003
                    (in thousands)                
BALANCE SHEET DATA:
                                       
Cash, cash equivalents and short-term investments
  $ 14,455     $ 45,994     $ 26,263     $ 8,483     $ 20,340  
Working capital
    14,982       46,056       26,591       12,544       22,039  
Total assets
    16,318       55,783       44,861       31,963       45,976  
Convertible preferred stock
    29,293                         27,032  
Stockholder’s equity (deficit)
    (13,502 )     54,143       43,055       29,913       16,944  

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ITEM 7. MANAGEMENT’S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND RESULTS OF OPERATIONS:

     We caution readers that statements in this Annual Report on Form 10-K that are not strictly historical statements, including, but not limited to: statements reflecting our expectations regarding the timing, cost, and success of our manufacturing scale-up at our new facility in Marlboro, Massachusetts and future manufacturing expansion and production, as well as related financing requirements; future financial performance; our technology and product development, cost and performance; our current and future strategic relationships and future market opportunities; and our other business and technology strategies and objectives, constitute forward-looking statements which are made pursuant to the safe harbor provisions of the Private Securities Litigation Reform Act of 1995. These statements may be identified with such words as “we expect”, “we believe”, “we anticipate” or similar indications of future expectations. These statements are neither promises nor guarantees and involve risks and uncertainties, which could cause our actual results to differ materially from such forward-looking statements. Such risks and uncertainties may include, among other things, those risks and uncertainties described in this Annual Report and in our other filings with the Securities and Exchange Commission, copies of which may be accessed through the SEC’s Web Site at http://www.sec.gov. We caution readers not to place undue reliance on any forward-looking statements contained in this Annual Report, which speak only as of the date of this Annual Report. We disclaim any obligation to publicly update or revise any such statements to reflect any change in our expectations, or events, conditions, or circumstances on which any such statements may be based, or that may affect the likelihood that actual results will differ from those set forth in such forward-looking statements.

EXECUTIVE OVERVIEW

     We develop, manufacture and market solar power products for the global marketplace. Solar cells are semiconductor devices that convert sunlight into electricity and form the building block for all solar power products. To date, our product sales have been primarily solar panels, which have been used to generate electricity for on-grid and off-grid applications. Off-grid applications have included the electrification of rural homes, lighting for small, rural schools and power supplies for water pumping. More recently, the substantial majority of our products have been used by on-grid customers as a clean, renewable source of alternative or supplemental electricity.

During 2003, our product sales were constrained by our manufacturing capacity. During the second half of 2003, we made significant progress on our capital expansion program aimed at roughly quadrupling our production capacity by adding a second manufacturing line, which we expect to be completed by the end of 2004. We completed a $29.5 million private equity financing on May 15, 2003 which will help fund this expansion. Since product revenue has been capacity limited, the planned expansion should enable significant revenue growth during 2004 and should also further improve our product gross margins.

In anticipation of the increase in product availability, we strengthened our sales and marketing organization with three hires during the fourth quarter of 2003, and are focused on expanding sales channels. The combination of recent governmental initiatives in Germany aimed at accelerating the adoption of solar power for residential and commercial applications, our proactive sales efforts, and our capacity expansion efforts should provide us with a foundation for product revenue growth in 2004.

     Implementation of our dual-ribbon growth technology, increased production volume, adding key positions to staff across the organization, expanding and establishing key customer relationships, and consummating the Series A convertible preferred stock and warrant financing were the key factors in determining our performance for 2003. We demonstrated the dual-ribbon growth technology (pulling two string ribbons out of one furnace) on a limited production basis during the fourth quarter in 2003, which we expect to substantially lower the manufacturing cost of growing silicon wafers and roughly double the capacity of one string ribbon furnace. We expect the new crystal growth furnaces we will be installing throughout 2004 will all be dual-ribbon growth furnaces. We added several key staff in sales, administration, manufacturing and research and development during 2003 to better position ourselves for the anticipated growth of the company over the next 12 months. Most notably, we hired Richard M. Feldt as our new President and CEO in December 2003. Additionally, our marketing and sales organization was expanded during the fourth quarter to develop our marketing and distribution strategy in anticipation of future growth.

The cash raised as a result of the Series A convertible preferred stock and warrant financing provided us with the resources necessary to increase our capital spending program. However, our current cash, cash equivalents and short-term investments will not be sufficient to fund this capacity expansion and our expected increased level of operations through fiscal year 2004 and, as a result, we will need to raise significant additional financing or secure a working capital line of credit in order to successfully fund such expanded operations. If we are not able to complete a financing or secure a working capital line of credit in a timely manner, we will need to implement fundamental changes to our business and operations which will likely include substantially reducing, suspending, or terminating our capacity expansion and substantially reducing our daily operating expenditures from current levels, in which case we believe our cash, cash equivalents and short-term investments will then be sufficient to fund our operations through the end of fiscal year 2004.

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We may need additional financing to execute our business plan sooner if we need to respond to business contingencies such as the need to enhance our operating infrastructure, respond to competitive pressures and acquire complementary businesses or necessary technologies. We do not know whether we will be able to raise additional financing or financing on terms favorable to us. If adequate funds are not available or are not available on acceptable terms, our ability to fund our operations, develop and expand our manufacturing operations and distribution network, or otherwise respond to competitive pressures would be significantly limited.

CRITICAL ACCOUNTING POLICIES AND ESTIMATES

     The preparation of consolidated financial statements in accordance with generally accepted accounting principals requires us to make estimates and judgments that affect the reported amounts of assets, liabilities, revenues and expenses, and related disclosure of contingent assets and liabilities. We base our estimates on historical experience and on various other assumptions that are believed to be reasonable under the circumstances, the results of which form the basis for making judgments about the carrying values of assets and liabilities that are not readily apparent from other sources. Actual results may differ from these estimates under different assumptions or conditions. We believe the following critical accounting policies affect our more significant judgments and estimates used in the preparation of our consolidated financial statements:

Revenue Recognition and Allowance for Doubtful Accounts

     We recognize product revenue if persuasive evidence of an arrangement exists, shipment has occurred, risk of loss has transferred to the customer, sales price is fixed or determinable, and collectibility is reasonably assured. The market for solar power products is emerging and rapidly evolving. We currently sell our solar power products primarily to distributors, system integrators and other value-added resellers within and outside of North America, which typically resell our products to end users throughout the world. For new customers requesting credit, we evaluate creditworthiness based on credit applications, feedback from provided references, and credit reports from independent agencies. For existing customers, we evaluate creditworthiness based on payment history and known changes in their financial condition.

     We also evaluate the facts and circumstances related to each sales transaction and consider whether risk of loss has not passed to the customer upon shipment. We consider whether our customer is purchasing our product for stock, and whether contractual or implied rights to return the product exist or whether our customer has an end user contractually committed. To date, we have not offered rights to return our products other than for normal warranty conditions.

     We maintain allowances for doubtful accounts for estimated losses resulting from the inability of our customers to make required payments. If the financial condition of our customers were to deteriorate, such that their ability to make payments was impaired, additional allowances could be required.

     Revenue from research grants is recognized as services are rendered to the extent of allowable costs incurred.

Inventory

     Inventory is valued at the lower of cost or market. Certain factors may impact the realizable value of our inventory including, but not limited to, technological changes, market demand, changes in product mix strategy, new product introductions and significant changes to our cost structure. Given our current production levels and the market value of our products, we currently sell our finished goods inventory at prices that are below the sum of our fixed and variable costs per unit. Accordingly, we write down our finished goods inventory to realizable value equal to the difference between the cost of inventory and the estimated market value. In addition, estimates of reserves are made for obsolescence based on the current product mix on hand and its expected net realizability. If actual market conditions are less favorable or other factors arise that are significantly different than those anticipated by management, additional inventory write-downs or increases in obsolescence reserves may be required. We treat lower of cost or market adjustments and inventory reserves as an adjustment to the cost basis of the underlying inventory. Accordingly, favorable changes in market conditions are not recorded to inventory in subsequent periods.

Warranty

     We provide for the estimated cost of product warranties at the time revenue is recognized. Given our limited operating history, we use historical industry solar panel failure rates as the basis for our warranty provision calculation. While we engage in product quality programs and processes, including monitoring and evaluating the quality of our component suppliers, our warranty obligation is affected by product failure rates and material usage and service delivery costs incurred in correcting a

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product failure. If our actual product failure rates, material usage or service delivery costs differ from our estimates, revisions to the estimated warranty liability would be required. Since we have a limited operating history and our manufacturing process differs from industry standards, our experience may be different from the industry data used as a basis for our estimate. While our methodology takes into account these uncertainties, adjustments in future periods may be required as our products mature.

Long-lived Assets

     Our policy regarding long-lived assets is to evaluate the recoverability or usefulness of these assets when the facts and circumstances suggest that these assets may be impaired. This analysis relies on a number of factors, including changes in strategic direction, business plans, regulatory developments, economic and budget projections, technological improvements, and operating results. The test of recoverability or usefulness is a comparison of the asset value to the undiscounted cash flow of its expected cumulative net operating cash flow over the asset’s remaining useful life. If such a test indicates that an impairment is required, then the asset is written down to its estimated fair value. Any write-downs would be treated as permanent reductions in the carrying amounts of the assets and an operating loss would be recognized. To date, we have had recurring operating losses and the recoverability of our long-lived assets is contingent upon executing our business plan that includes further reducing our manufacturing costs and significantly increasing sales. If we are unable to execute our business plan, we may be required to write down the value of our long-lived assets in future periods.

Income Taxes

     We are required to estimate our income taxes in each of the jurisdictions in which we operate as part of our consolidated financial statements. This involves estimating the actual current tax in addition to assessing temporary differences resulting from differing treatments for tax and financial accounting purposes. These differences together with net operating loss carryforwards and tax credits may be recorded as deferred tax assets or liabilities on the balance sheet. A judgment must then be made of the likelihood that any deferred tax assets will be recovered from future taxable income. To the extent that we determine that it is more likely than not that deferred tax assets will not be utilized, a valuation allowance is established. Taxable income in future periods significantly different from that projected may cause adjustments to the valuation allowance that could materially increase or decrease future income tax expense.

Results of Operations

     Product revenues. Product revenues consist of revenues from the sale of solar cells, panels and systems. Product revenues represented 83% of total revenues for the year ended December 31, 2003, 79% of total revenues for the year ended December 31, 2002 and 62% of total revenues for the year ended December 31, 2001. International product sales accounted for approximately 73%, 68% and 35% of total product revenues for the years ended December 31, 2003, 2002 and 2001, respectively. During 2003, product sales to a European distributor accounted for approximately 47% of product revenue, and sales to another European distributor accounted for approximately 10% of product revenue. During 2002, sales to a European distributor accounted for approximately 56% of product revenue. During 2001, sales to a U.S. distributor and a Japanese distributor accounted for approximately 52% and 22% of product revenue, respectively. We anticipate that international sales will continue to account for a significant portion of our product revenues for the foreseeable future. Through December 31, 2003, all product revenues were denominated in United States dollars. Foreign exchange rate fluctuations have impacted the relative competitiveness of our products in international markets, but we have not had any direct foreign exchange exposure. However, we expect that during 2004, market conditions will require us to denominate a portion of our sales in local currencies, which could expose us directly to foreign exchange gains or losses. As we expand our manufacturing operations and distribution network internationally, our exposure to fluctuations in currency exchange rates may increase.

     Research revenues. Research revenues consist of revenues from various state and federal government agencies to fund our ongoing research, development, testing and enhancement of our products and manufacturing technology. We have not in the past, nor is it our intention in the future, to pursue contracts that are not part of our ongoing research activities. We recognize research revenues as services are rendered. During 2003, we had two active multi-year research contracts summarized as follows (in millions):

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    National Institute    
    of Standards and   National Renewable
    Technology
  Energy Laboratory
Total government funding
  $ 2.0     $ 3.0  
Total funding authorized as of December 31, 2003
  $ 2.0     $ 2.0  
Revenue recorded through December 31, 2003
  $ 2.0     $ 1.6  
Remaining revenue to be recorded
  $ 0.0     $ 1.4  
Expiration date
  October 31, 2003   May 31, 2005

     We have fully recognized all revenue associated with our contract with the National Institute of Standards and Technology which expired on October 31, 2003, and we expect the remaining $1.4 million of revenue associated with the contract with the National Renewable Energy Laboratory will be recognized as work is performed over the remaining life of the contract, which expires on May 31, 2005.

     Cost of product revenues. Cost of product revenues consists primarily of salaries and related personnel costs, materials expenses, depreciation expenses, maintenance, rent, royalties on licensed technology, warranty costs and other support expenses associated with the manufacture of our solar power products. We expect to continue to experience costs in excess of product revenues unless we are able to achieve greater manufacturing efficiencies, higher yields and higher production levels.

     Research and development expenses, including cost of research revenues. Research and development expenses, including cost of research revenues, consist primarily of salaries and related personnel costs, consulting expenses and prototype costs related to the design, development, testing and enhancement of our products and manufacturing technology. We expense our research and development costs as incurred. We believe that research and development is critical to our strategic objectives of enhancing our technology, reducing manufacturing costs and meeting the changing requirements of our customers. As a result, we expect that our total research and development expenses will increase in the future.

     Selling, general and administrative expenses. Selling, general and administrative expenses consist primarily of salaries and related personnel costs, professional fees, rent, insurance and other sales expenses. We expect that selling expenses will increase substantially in absolute dollars as we increase our sales efforts, hire additional sales personnel and initiate additional marketing programs. We expect that general and administrative expenses will increase as we add personnel and incur additional costs related to the growth of our business as well as increased compliance costs associated with being a publicly traded company.

     Stock-based compensation expense, related to the issuance of stock options to employees. Prior to December 31, 2000, we recorded total cumulative deferred compensation of approximately $1.3 million representing the difference between the estimated fair market value of the common stock and the exercise price of the option at the grant date. These amounts were presented as a reduction of stockholders’ equity and are being amortized ratably over the vesting period of the options, which is generally four years. The amortization resulted in charges to operations of $271,000, $289,000, and $290,000 for the years ended December 31, 2003, 2002, and 2001, respectively, and is reflected in operating expenses. We expect to recognize stock-based compensation expense for these past grants of approximately $90,000 for the year ending December 31, 2004.

     Net interest income. Net interest income consists primarily of interest earned on the holding of short-term, high quality commercial paper, corporate bonds and United States government-backed securities, less any bond premium amortization.

COMPARISON OF YEARS ENDED DECEMBER 31, 2003 AND 2002

     Revenues. Our product revenues for the year ended December 31, 2003 were $7.7 million, an increase of $2.5 million, or 46%, from $5.3 million for the same period in 2002. The increase in product revenues was due to the increased production capacity of our manufacturing facility in Marlboro, Massachusetts, and our increased marketing and sales activities. Research revenues for the year ended December 31, 2003 were $1.6 million, an increase of $117,000, or 8%, from $1.4 million for the

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same period in 2002. The increase in research revenue was due to revenue recognized associated with our research contract with the National Renewable Energy Laboratory, for which work did not begin until late 2002.

     Cost of product revenues. Our cost of product revenues for the year ended December 31, 2003 was $15.4 million, an increase of $3.0 million, or 24%, from $12.4 million for the same period in 2002. This increase was associated with increased production at our Marlboro facility. Approximately 25% of the increase was due to higher depreciation expense resulting from equipment placed in service at our Marlboro manufacturing facility, approximately 50% of the increase was due to increases in materials purchased due to increased production, and most of the remainder was due to increases in salaries associated with additional personnel. Product gross margin for the year ended December 31, 2003 was –99% versus -134% for the same period in 2002. Product gross margin improved primarily due to yield and efficiency improvements associated with the scale-up of our manufacturing line and higher sales volumes. Due to the relatively large component of fixed costs and scale-up of our production, product gross margins will still be highly dependent on sales volumes. Therefore, we do not expect substantial improvements in product gross margin until we realize increased production volumes associated with the completion of our second manufacturing line, expected by the end of 2004.

     Research and development expenses, including cost of research revenues. Our research and development expenses, including cost of research revenues, for the year ended December 31, 2003 were $3.8 million, an increase of $99,000, or 3%, from $3.7 million for the same period in 2002. The increase was due primarily to increased activity associated with our two active government contracts, as more costs were incurred for subcontractors providing research services as well as for added personnel.

     Selling, general and administrative expenses. Our selling, general and administrative expenses for the year ended December 31, 2003 were $5.3 million, an increase of $817,000, or 18%, from $4.5 million in 2002. Approximately 50% of the increase was due to increases in insurance costs, approximately 20% of the increase was due to increases in advertising and other marketing programs, and most of the remainder of the increase was due to higher professional service fees.

     Net interest income. Our net interest income for the year ended December 31, 2003 was $222,000, a decrease of $452,000, or 67%, from $674,000 for the same period in 2002. The decrease in interest income was due to declining cash and investment balances for a portion of the period resulting from capital equipment purchases and funding of operations and generally lower yields realized on marketable securities.

     Accretion and dividends on preferred stock. On May 15, 2003, we issued 26,227,668 shares of Series A convertible preferred stock at a per share purchase price of $1.12. Additionally, Beacon Power Corporation purchased a warrant to purchase 2,400,000 shares of common stock at an exercise price equal to $3.37 per share for $100,000. A total of $29.5 million was raised as a result of the consummation of the transaction, which was partially offset by financing costs of $849,000. As a result of the preferred stock financing, accretion and dividends of $13.5 million were recorded through December 31, 2003. $11.7 million of this charge relates to accretion that was recognized immediately (during the second quarter of 2003) because the holders of shares of the Series A convertible preferred stock are entitled to convert their shares into common stock at any time. The sources of the discounts on issuance requiring this accretion charge are summarized in the following table:

         
Beneficial conversion feature
  $ 10,314,000  
Proceeds allocated to the fair value of common stock warrant
    525,000  
Financing costs
    849,000  
 
   
 
 
Total preferred stock accretion and dividends
  $ 11,688,000  
 
   
 
 

     The difference between the issuance price of the Series A convertible preferred stock and the fair value of our common stock on the date of issuance of the Series A convertible preferred stock resulted in a beneficial conversion feature totaling approximately $10.3 million, which was calculated in accordance with EITF 00-27, Application of Issue No. 98-5 to Certain Convertible Instruments

     The total proceeds of $1.1 million from Beacon Power Corporation were allocated between the Series A convertible preferred stock (approximately $475,000) and the warrant (approximately $625,000) based on their relative fair values. The value of the warrant was calculated using the Black-Scholes pricing model with the following assumptions: dividend yield of zero percent; expected volatility of 90%; risk free interest rate of approximately 2% and a term of three years. The difference between the proceeds allocated to the relative fair value of the warrant, $625,000, and the amount paid for the warrant, $100,000, or $525,000 contributed to the accretion charge of $11.7 million for the year ended December 31, 2003.

     Shares of Series A convertible preferred stock pay a compounding dividend of 10% per annum, paid quarterly, in cash, or at our election to be added to the liquidation preference of the Series A convertible preferred stock on a quarterly basis, which

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would result in an increase in the number of shares of common stock issuable upon conversion of the Series A convertible preferred stock. For the year ended December 31, 2003, $1.8 million in dividends accrued on the outstanding Series A convertible preferred stock, which we elected to add to the liquidation preference of the Series A convertible preferred stock. Subject to changes in business conditions, we presently anticipate that the dividend will be added to the liquidation preference of the Series A convertible preferred stock for the foreseeable future.

     Net loss attributable to common stockholders. Net loss attributable to common stockholders was $28.5 million and $13.2 million for the years ending December 31, 2003 and December 31, 2002, respectively. The increase in net loss attributable to common stockholders was due to the overall increase in net operating losses associated with the scale-up of our operations combined with the accretion and dividend charges associated with the Series A convertible preferred stock financing, which was consummated on May 15, 2003.

     Other comprehensive loss. Our other comprehensive loss for the year ended December 31, 2003 was $34,000, compared to $242,000 for the same period in 2002, consisting of net unrealized losses on marketable securities.

COMPARISON OF YEARS ENDED DECEMBER 31, 2002 AND 2001

     Revenues. Our product revenues for the year ended December 31, 2002 were $5.3 million, an increase of $3.8 million, or 243%, from $1.5 million for the same period in 2001. The increase in product revenues was due to the increased production capacity of our manufacturing facility in Marlboro, Massachusetts, and our increased marketing and sales activities. Research revenues for the year ended December 31, 2002 were $1.4 million, an increase of $516,000, or 55%, from $932,000 for the same period in 2001. The increase in research revenues reflects revenue recognized on a research contract with the National Renewable Energy Laboratory accrued in 2002.

     Cost of product revenues. Our cost of product revenues for the year ended December 31, 2002 was $12.4 million, an increase of $2.8 million, or 29%, from $9.6 million for the same period in 2001. This increase was associated with increased production at our Marlboro facility. Approximately one third of the increase was due to higher depreciation expense resulting from equipment placed in service at our Marlboro manufacturing facility, approximately one half of the increase was due to increases in materials purchased due to increased production, and most of the remainder was due to increases in salaries associated with additional personnel.

     Research and development expenses, including cost of research revenues. Our research and development expenses, including cost of research revenues, for the year ended December 31, 2002 were $3.7 million, an increase of $629,000, or 21%, from $3.1 million for the same period in 2001. The increase was due primarily to the addition of employees and increased spending on both contract related and non-contract related research and development projects.

     Selling, general and administrative expenses. Our selling, general and administrative expenses for the year ended December 31, 2002 were $4.5 million, an increase of $432,000, or 11%, from $4.1 million in 2001. Approximately 20% of the increase was due to increases in insurance costs, approximately 33% of the increase was due to increases in salary and other costs associated with the establishment of our Germany sales office, and the remainder of the increase was due to higher depreciation and professional service fees (including audit and legal fees).

     Net interest income. Our net interest income for the year ended December 31, 2002 was $674,000, a decrease of $1.2 million, or 63%, from $1.8 million for the same period in 2001. The decrease in interest income was due to declining cash and investment balances resulting from capital equipment purchases and funding of operations.

     Net loss attributable to common stockholders. Net loss attributable to common stockholders was $13.2 million and $12.5 million for the years ending December 31, 2003 and December 31, 2002, respectively. The increase in net loss attributable to common stockholders was due primarily to a decrease in interest income resulting from declining cash and investment balances resulting from capital equipment purchases and funding of operations.

     Other comprehensive income (loss). Our other comprehensive loss for the year ended December 31, 2002 was $242,000, compared to other comprehensive income of $249,000 for the same period in 2001, consisting of net unrealized gains and losses on marketable securities.

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LIQUIDITY AND CAPITAL RESOURCES

Financing Transaction

     On May 15, 2003, we consummated a private placement financing transaction with Perseus 2000, L.L.C., Nth Power Technologies Fund II, LP, Nth Power Technologies Fund II-A, LP, RockPort Capital Partners, L.P., RP Co-Investment Fund, I, Micro-Generation Technology Fund, LLC, UVCC Fund II, UVCC II Parallel Fund, L.P., Caisse de depot et placement du Quebec, CDP Capital - Technology Ventures U.S. Fund 2002 L.P., Beacon Power Corporation, Massachusetts Technology Park Corporation, Zero Stage Capital VII, L.P., Zero Stage Capital (Cayman) VII, L.P., Zero Stage Capital SBIC VII, L.P., IMPAX Environmental Markets plc, Merrill Lynch New Energy Technology Plc, MLIIF New Energy Fund, PNE Invest Limited, Odyssey Fund, SAM Private Equity Energy Fund LP, SAM Sustainability Private Equity LP and SAM Smart Energy. As a result of the consummation of this transaction, on May 15, 2003, we issued 26,227,668 shares of Series A convertible preferred stock at a per share purchase price of $1.12. Additionally, Beacon Power Corporation purchased a warrant to purchase 2,400,000 shares of common stock at an exercise price equal to $3.37 per share for $100,000. A total of $29.5 million was raised as a result of the consummation of the transaction. The proceeds to us, net of financing expenses of approximately $849,000, were approximately $28.6 million. The shares of Series A convertible preferred stock were initially convertible into shares of common stock on a 1-to-1 basis which is subject to adjustment to account for the payment of dividends, to take into account certain changes to our capital structure and to account for future dilutive issuances. As a condition to the obligation of the purchasers to consummate the financing transaction, we registered for resale the shares of common stock issuable upon the conversion of the Series A convertible preferred stock and the exercise of the warrant.

     We have historically financed our operations and met our capital expenditures requirements primarily through sales of our capital stock and, to a lesser extent, product revenues. Research and development expenditures have historically been partially funded by government research contracts. At December 31, 2003, we had working capital of $22.0 million, including cash, cash equivalents and short-term investments of $20.3 million.

     Net cash used in operating activities was $9.4 million for the year ended December 31, 2003, $14.3 million for the year ended December 31, 2002, and $11.4 million for the year ended December 31, 2001. The decrease in net cash used in operating activities in fiscal year 2003 as compared with fiscal year 2002, was primarily due to a decrease in our accounts receivable and other current assets. As of December 31, 2003, Days Sales Outstanding (DSO) was approximately 38 days, versus approximately 152 days as of December 31, 2002. The decrease in DSO reflects a significant amount of cash receipts during the fourth quarter relating to sales made in prior quarters, combined with a decrease in product revenue in the fourth quarter from the third quarter. However, international customers are commonly offered longer payment terms than domestic customers due to established business practices, and DSO in future periods may fluctuate depending on the mix of international versus domestic sales as well as the timing of when such sales are made. In general, we anticipate DSO in excess of 60 days during 2004.

     Net cash used in investing activities was $15.8 million for the year ended December 31, 2003, compared to net cash provided by investing activities of $12.9 million for the year ended December 31, 2002, and net cash used in investing activities of $16,000 for the year ended December 31, 2001. For the year ended December 31, 2003, net cash was used to purchase equipment associated with the build-out of the second manufacturing line at our Marlboro manufacturing plant as well as the purchase of marketable securities partially offset by the maturity and sales of marketable securities. For the year ended December 31, 2002, net cash was provided by maturing and selling short-term investments as required to fund operations and purchases of equipment associated with the build-out of the second manufacturing line at our Marlboro manufacturing plant, offset by purchases of corporate paper, corporate bonds and United States government-backed obligations with contractual maturities typically less than one year. For the year ended December 31, 2001, net cash used in investing activities primarily represented capital expenditures associated with the build-out of our manufacturing facility in Marlboro, and also included purchases, sales and maturities of marketable securities.

     Net cash provided by financing activities was $28.6 million for the year ended December 31, 2003, $10,000 for the year ended December 31, 2002, and $812,000 for the year ended December 31, 2001. For the year ended December 31, 2003, cash provided by financing activities principally represented the net proceeds resulting from our Series A convertible preferred stock and warrant financing which closed on May 15, 2003. During 2002 and 2001, cash provided by financing activities represents proceeds from common stock shares issued under our Employee Stock Purchase Plan, and proceeds from the exercise of options and warrants to purchase common stock.

     Capital expenditures were $7.1 million for the year ended December 31, 2003, $2.9 million for the year ended December 31, 2002, and $9.4 million for the year ended December 31, 2001. Capital expenditures for the year ended December 31, 2003 were primarily for equipment needed for our manufacturing facility. As of December 31, 2003, our outstanding commitments for capital expenditures were approximately $3.0 million. Nearly all of our commitments for capital expenditures are associated with infrastructure improvements and equipment purchases for our manufacturing facility. The first of the Marlboro

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facility’s two manufacturing lines became operational in 2001. We have purchased certain equipment that is planned for the second manufacturing line. We will fund our current capital commitments primarily with the proceeds from our Series A convertible preferred stock and warrant financing which closed on May 15, 2003. In addition to the current capital commitments, substantial further capital expenditures will be required over the next twelve months to increase the capacity at our manufacturing facility to our target level of 10 to 14 megawatts for both lines. We expect the second manufacturing line will be completed in 2004. However, our current cash, cash equivalents and short-term investments will not be sufficient to fund this capacity expansion and our expected increased level of operations through fiscal year 2004 and, as a result, we will need to raise significant additional financing or secure a working capital line of credit in order to successfully fund such expanded operations. If we are not able to complete a financing or secure a working capital line of credit in a timely manner, we will need to implement fundamental changes to our business and operations which will likely include substantially reducing, suspending, or terminating our capacity expansion and substantially reducing our daily operating expenditures from current levels, in which case we believe our cash, cash equivalents and short-term investments will then be sufficient to fund our operations through the end of fiscal year 2004.

     We need additional financing to execute our business plan and to respond to business contingencies such as the need to enhance our operating infrastructure, respond to competitive pressures and acquire complementary businesses or necessary technologies. In addition to the current capital commitments, substantial further capital expenditures will be required over the next twelve months to increase the capacity at our manufacturing facility to our target level of 10 to 14 megawatts for both lines. We do not know whether we will be able to raise additional financing or financing on terms favorable to us. If adequate funds are not available or are not available on acceptable terms, our ability to fund our operations, develop and expand our manufacturing operations and distribution network, or otherwise respond to competitive pressures would be significantly limited.

     We currently do not have any special purpose entities or off-balance sheet financing arrangements.

     The following table summarizes our contractual obligations as of December 31, 2003 and the effect such obligations are expected to have on our liquidity and cash flow in future periods:

                                         
    Total   Less than            
    Years
  1 Year
  1-3 Years
  4-5 Years
  After 5 Years
Non-cancelable operating lease
  $ 4,082,161     $ 628,765     $ 1,965,732     $ 1,359,707     $ 292,020  
Minimum future royalty payments
    25,000       25,000                          
Capital expenditure obligations
    3,000,000       3,000,000                          
Raw materials purchase commitments
    2,200,000       2,200,000                          
 
   
 
     
 
     
 
     
 
     
 
 
Total contractual cash obligations
  $ 9,307,161     $ 5,853,765     $ 1,975,107     $ 1,364,394     $ 113,895  
 
   
 
     
 
     
 
     
 
     
 
 

INCOME TAXES

     As of December 31, 2003, we had federal and state net operating loss carryforwards totaling approximately $47.9 million and $39.9 million, respectively, available to reduce future taxable income and tax liabilities which expire at various dates between 2004 and 2023. In addition, as of December 31, 2003 we had federal and state research and development tax credit carryforwards of approximately $804,000 and $433,000, respectively, available to reduce future taxable income and tax liabilities which expire at various dates between 2009 and 2023. Under provisions of the Internal Revenue Code, substantial changes in our ownership may limit the amount of net operating loss carryforwards and research and development credit carryforwards, which can be used annually to offset future taxable income and income tax liability. We have evaluated the positive and negative evidence bearing upon the realizability of our deferred tax assets. We have considered our history of losses and, in accordance with the applicable accounting standards, have fully reserved the deferred tax asset.

RECENT ACCOUNTING PRONOUNCEMENTS

     In November 2002, the FASB issued Emerging Issues Task Force 00-21 (“EITF 00-21”), “Accounting for Revenue Arrangements with Multiple Deliverables.” EITF 00-21 requires revenue arrangements with multiple deliverables to be divided into separate units of accounting. If the deliverables in the arrangement meet certain criteria, arrangement consideration should be allocated among the separate units of accounting based on their relative fair values. Applicable revenue recognition criteria are to be considered separately for separate units of accounting. The guidance in EITF 00-21 was effective for revenue arrangements entered into in fiscal periods beginning after June 15, 2003. The adoption of EITF 00-21 did not have a material impact on our financial position or results of operations.

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     In January 2003, the FASB issued Interpretation (“FIN”) No. 46, “Consolidation of Variable Interest Entities” (“FIN 46”) and, in December 2003, issued a revision to that interpretation (“FIN 46R”). FIN 46R replaces FIN 46 and addresses consolidation by business enterprises of variable interest entities that possess certain characteristics. A variable interest entity (“VIE”) is defined as (a) an ownership, contractual or monetary interest in an entity where the ability to influence financial decisions is not proportional to the investment interest, or (b) an entity lacking the invested capital sufficient to fund future activities without the support of a third party. FIN 46R establishes standards for determining under what circumstances VIEs should be consolidated with their primary beneficiary, including those to which the usual condition for consolidation does not apply. The adoption of FIN 46R did not have a material impact on our financial position or results of operations.

     On December 17, 2003, the Staff of the Securities and Exchange Commission (“SEC”) issued Staff Accounting Bulletin No. 104 (SAB 104), “Revenue Recognition”, which supersedes SAB 101, “Revenue Recognition in Financial Statements.” SAB 104’s primary purpose is to rescind the accounting guidance contained in SAB 101 related to multiple-element revenue arrangements that was superseded as a result of the issuance of EITF 00-21, “Accounting for Revenue Arrangements with Multiple Deliverables.” Additionally, SAB 104 rescinds the SEC’s related “Revenue Recognition in Financial Statements Frequently Asked Questions and Answers” issued with SAB 101 that had been codified in SEC Topic 13, “Revenue Recognition.” While the wording of SAB 104 has changed to reflect the issuance of EITF 00-21, the revenue recognition principles of SAB 101 remain largely unchanged by the issuance of SAB 104, which was effective upon issuance. The adoption of SAB 104 did not have a material effect on our financial position or results of operations.

Certain Factors Which May Affect Future Results

Risks Relating to Our Financial Results

Evaluating our business and future prospects may be difficult due to our limited operating history.

We are at an early stage of development and there is limited historical information available upon which you can base your evaluation of our business and prospects. We were formed in 1994 to research and develop crystalline silicon technology for use in manufacturing solar power products. Although we began shipping product from our pilot manufacturing facility in 1997, the primary objective of our pilot production line was the technical development and further refinement of our String Ribbon technology and related manufacturing processes. We shipped our first commercial products from our Marlboro manufacturing facility in September 2001. We have shipped only a limited number of solar power panels and have recognized limited revenues since our inception.

In addition, our early stage of development means that we have less insight into how market and technology trends may affect our business. The revenue and income potential of our business is unproven and the market we are addressing is rapidly evolving. You should consider our business and prospects in light of the risks, expenses and challenges that we will face as an early-stage company seeking to develop and manufacture new products in a growing and rapidly evolving market.

We have a history of losses, expect to incur substantial further losses and may not achieve or maintain profitability in the future, which may decrease the market value of our stock.

Since our inception, we have incurred significant net losses, including net losses of $15.0 million for the year ended December 31, 2003. As a result of ongoing operating losses, we had a cumulative net loss of $56.3 million as of December 31, 2003. We expect to incur substantial losses for the foreseeable future, and may never become profitable. Even if we do achieve profitability, we may be unable to sustain or increase our profitability in the future, which could materially decrease the market value of our common stock. We expect to continue to incur significant capital expenditures and anticipate that our expenses will increase substantially in the foreseeable future as we seek to: expand our manufacturing operations, develop our distribution network, continue to research and develop our products and manufacturing technologies, implement internal systems and infrastructure in conjunction with our growth and hire additional personnel.

We do not know whether our revenues will grow at all or grow rapidly enough to absorb these expenses, and our limited operating history makes it difficult to assess the extent of these expenses or their impact on our operating results.

Our stock price could fall substantially if our quarterly revenue or operating results fluctuate or are disappointing.

Our quarterly revenue and operating results have fluctuated significantly in the past and may fluctuate significantly from quarter to quarter in the future due to a variety of factors, many of which are discussed elsewhere in this section.

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We anticipate that our operating expenses will continue to increase significantly. If sales in any quarter do not increase correspondingly, our net losses for that period will increase. For these reasons, quarter-to-quarter comparisons of our results of operations are not necessarily meaningful and you should not rely on results of operations in any particular quarter as an indication of future performance. If our quarterly revenue or results of operations fall below the expectations of investors or public market analysts in any quarter, the market value of our common stock would likely decrease, and could decrease rapidly and substantially.

Risks Relating to Our Industry, Products and Operations

We have significant capital requirements in order to maintain and grow our business.

     On May 15, 2003, we consummated a private placement financing transaction that raised $29.5 million (before offering expenses of $849,000) through the issuance of 26,227,668 shares of Series A convertible preferred stock and the sale of a warrant to purchase 2,400,000 shares of our common stock. We will fund our current capital commitments primarily with the proceeds from our Series A convertible preferred stock and warrant financing. However, our current cash, cash equivalents and short-term investments will not be sufficient to fund this capacity expansion and our expected increased level of operations through fiscal year 2004 and, as a result, we will need to raise significant additional financing or secure a working capital line of credit in order to successfully fund such expanded operations. If we are not able to complete a financing or secure a working capital line of credit in a timely manner, we will need to implement fundamental changes to our business and operations which will likely include substantially reducing, suspending, or terminating our capacity expansion and substantially reducing our daily operating expenditures from current levels, in which case we believe our cash, cash equivalents and short-term investments will then be sufficient to fund our operations through the end of fiscal year 2004.

We need additional financing to execute our business plan and to respond to business contingencies such as the need to enhance our operating infrastructure, respond to competitive pressures and acquire complementary businesses or necessary technologies. In addition to our current capital commitments, substantial further capital expenditures will be required over the next twelve months to increase the capacity at our manufacturing facility to our target level of 10 to 14 megawatts for both lines. We do not know whether we will be able to raise additional financing or financing on terms favorable to us. If adequate funds are not available or are not available on acceptable terms, our ability to fund our operations, develop and expand our manufacturing operations and distribution network, or otherwise respond to competitive pressures would be significantly limited. In addition, if we raise additional funds through the issuance of equity or convertible debt securities, the percentage ownership of our existing stockholders will be reduced. These newly issued securities may have rights, preferences and privileges senior to those of existing stockholders.

If solar power technology is not suitable for widespread adoption or sufficient demand for solar power products does not develop or takes longer to develop than we anticipate, our sales would not significantly increase and we would be unable to achieve or sustain profitability.

The market for solar power products is emerging and rapidly evolving, and its future success is uncertain. If solar power technology proves unsuitable for widespread commercial deployment or if demand for solar power products fails to develop sufficiently, we would be unable to generate enough revenues to achieve and sustain profitability. In addition, demand for solar power products in the markets and geographic regions we target may not develop or may develop more slowly than we anticipate. Many factors will influence the widespread adoption of solar power technology and demand for solar power products, including:

-   cost-effectiveness of solar power technologies as compared with conventional and non-solar alternative energy technologies;
 
-   performance and reliability of solar power products as compared with conventional and non-solar alternative energy products;
 
-   success of alternative distributed generation technologies such as fuel cells, wind power and micro turbines;
 
-   fluctuations in economic and market conditions which impact the viability of conventional and non-solar alternative energy sources, such as increases or decreases in the prices of oil and other fossil fuels;
 
-   continued deregulation of the electric power industry and broader energy industry; and
 
-   availability of government subsidies and incentives.

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Problems with product quality or product performance may cause us to incur warranty expenses and may damage our market reputation and prevent us from achieving increased sales and market share.

As is consistent with standard practice in our industry, the duration of our product warranties is lengthy relative to expected product life and has recently been increasing. Our current standard product warranty includes a one or two-year warranty period for defects in material and workmanship and a 25-year warranty period for declines in power performance. We believe our warranty periods are consistent with industry practice. Due to the long warranty period, we bear the risk of extensive warranty claims long after we have shipped product and recognized revenues. Although we have sold over 50,000 solar panels since 1997, none of these panels has been operating more than six years, and over 50% of them have been operating less than one year. The possibility of future product failures could cause us to incur substantial expense to repair or replace defective products. Furthermore, widespread product failures may damage our market reputation and reduce our market share and cause sales to decline.

We may fail to successfully bring to market our new solar power products under development, which may prevent us from achieving increased sales and market share.

Although we have been selling our solar power products since 1997, we expect to derive a substantial portion of our revenues from sales of our new solar power products which are under development and not yet commercially available. Many of these new products are derived from our innovative cell fabrication and advanced panel design technologies, which are under development. If we fail to successfully develop our new solar power products or technologies, we will likely be unable to recover the losses we will have incurred to develop these products and technologies and may be unable to increase our sales and market share and to become profitable. Many of our new product and manufacturing technologies are novel and represent a departure from conventional solar power technologies, and it is difficult to predict whether we will be successful in completing their development. Our manufacturing technologies have been tested only in our pilot manufacturing facility and, in most cases, only limited pre-production prototypes of our new products have been field-tested.

Our solar power products may not gain market acceptance, which would prevent us from achieving increased sales and market share.

The development of a successful market for our solar power products may be adversely affected by a number of factors, many of which are beyond our control, including:

-   our failure to produce solar power products which compete favorably against other solar power products on the basis of cost, quality and performance;
 
-   our failure to produce solar power products which compete favorably against conventional energy sources and alternative distributed generation technologies, such as fuel cells, on the basis of cost, quality and performance;
 
-   whether customers accept our new panel designs under development and the techniques we are developing to mount them; and
 
-   our failure to develop and maintain successful relationships with distributors, systems integrators and other resellers, as well as strategic partners.

If our solar power products fail to gain market acceptance, we would be unable to increase our sales and market share and to achieve and sustain profitability.

Technological changes in the solar power industry could render our solar power products obsolete, which could reduce our market share and cause our sales to decline.

Our failure to further refine our technology and develop and introduce new solar power products could cause our products to become obsolete, which could reduce our market share and cause our sales to decline. The solar power industry is rapidly evolving and competitive. We will need to invest significant financial resources in research and development to keep pace with technological advances in the solar power industry and to effectively compete in the future. We believe that there are a variety of competing solar power technologies under development by other companies that could result in lower manufacturing costs than those expected for our solar power products. Our development efforts may be rendered obsolete by the technological advances of others, and other technologies may prove more advantageous for the commercialization of solar power products.

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The build-out of our manufacturing facility may take longer and cost more than we expect, which would likely result in lower revenues and earnings than anticipated.

If we fail to successfully complete the build-out of our Marlboro manufacturing facility, our business and results of operations would likely be materially impaired. The first of the Marlboro facility’s two manufacturing lines entered service in 2001. The Company expects the second manufacturing line to be completed in 2004. Completing the build-out of this facility to capacity will require a significant investment of capital and substantial engineering expenditures, and is subject to significant risks, including risks of cost overruns, delays, equipment problems and other start-up and operating difficulties. Our manufacturing processes also use custom-built equipment that may not be delivered and installed in our new facility in a timely manner. In addition, this equipment may take longer and cost more to debug than planned and may never operate as designed. We plan to incorporate first-time equipment designs and technology improvements, which we expect to lower unit capital and operating costs, but this new technology may not be successful, which would increase cost, limit capacity, and prevent us from achieving increases in sales. If we experience any of these or similar difficulties, we may be unable to complete the build-out of the facility, our manufacturing capacity could be substantially constrained and our revenues and earnings would likely be materially impaired.

We may not be able to manufacture our solar power products in sufficient quantities or at acceptable costs to meet customer demand.

We may not be able to achieve our manufacturing cost targets, which could prevent us from ever becoming profitable. If we cannot achieve our targeted production volumes or capacity or if we experience capacity constraints, quality control problems or other disruptions, we may not be able to manufacture our products in large volumes or at acceptable costs and may be unable to satisfy the demand of our customers, which would reduce our market share and revenues and may harm our reputation. The expansion of our manufacturing operations to achieve targeted production volumes will require the successful deployment of advanced equipment and technology utilizing manufacturing processes and components, which we are currently developing.

Our ability to increase market share and sales depends on our ability to successfully maintain our existing distribution relationships and expand our distribution channels.

We currently sell our solar power products primarily to distributors, system integrators and other value-added resellers within and outside of North America, which typically resell our products to end users on a global basis. For the year ended December 31, 2003, we sold our solar power products to approximately 25 distributors, system integrators and other value-added resellers. If we are unable to successfully maintain our existing distribution relationships and expand our distribution channels, our revenues and future prospects will be materially harmed. As we seek to grow our sales by entering new markets in which we have little experience selling our solar power products, our ability to increase market share and sales will depend substantially on our ability to expand our distribution channels by identifying, developing and maintaining relationships with resellers both within and outside of North America. We may be unable to enter into relationships with resellers in the markets we target or on terms and conditions favorable to us, which could prevent us from entering these markets or entering these markets in accordance with our plans. Our ability to enter into and maintain relationships with resellers will be influenced by the relationships between these resellers and our competitors, market acceptance of our solar power products and our low brand recognition as a new entrant.

We face risks associated with the marketing, distribution and sale of our solar power products internationally, and if we are unable to effectively manage these risks, it could impair our ability to expand our business abroad.

From our inception through December 31, 2003, approximately 67% of our product sales have been made to resellers outside North America. We expect that our sales both to resellers and distributors outside of North America and through our resellers and distributors to end users outside of North America will continue to be significant. Sales in Germany constituted approximately 63% of our total product sales for the year ended December 31, 2003. It will require significant management attention and financial resources to successfully develop our international sales channels. In addition, the marketing, distribution and sale of our solar power products internationally exposes us to a number of markets with which we have limited experience. If we are unable to effectively manage these risks, it could impair our ability to grow our business abroad. These risks include:

-   difficult and expensive compliance with the commercial and legal requirements of international markets, with which we have only limited experience;
 
-   inability to obtain intellectual property protection;

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-   encountering trade barriers such as export requirements, tariffs, taxes and other restrictions and expenses, which could affect the competitive pricing of our solar power products and reduce our market share in some countries;
 
-   difficulty of enforcing revenue collection internationally; and
 
-   our continued ability to sell our products in the German market.

We expect that a portion of our international sales will be denominated in United States dollars. As a result, increases in the value of the United States dollar relative to foreign currencies would cause our products to become less competitive in international markets and could result in limited, if any, sales and profitability. We expect that during 2004, market conditions will require us to denominate a majority of our sales in local currencies, which will further expose us to foreign exchange gains or losses.

Our strategy includes establishing local manufacturing facilities in international markets, although we have not yet done so. As we implement our strategy, we may encounter legal and commercial restrictions and incur taxes and other expenses to establish our manufacturing facilities in certain countries. In addition, we may potentially forfeit, voluntarily or involuntarily, foreign assets due to economic or political instability in the countries where our local manufacturing facilities are located.

Our dependence on a small number of resellers may cause significant fluctuations or declines in our product revenues.

From our inception through December 31, 2003, our three largest resellers accounted for approximately 57% of our product sales and our 10 largest resellers accounted for approximately 82% of our product sales. We anticipate that sales of our solar power products to a limited number of key resellers will continue to account for a significant portion of our total product revenues for the foreseeable future. Consequently, any one of the following events may cause significant fluctuations or declines in our product revenues:

-   reduction, delay or cancellation of orders from one or more of our significant resellers;
 
-   selection by one or more of our significant resellers of products competitive with ours;
 
-   loss of one or more of our significant resellers and our failure to recruit additional or replacement resellers; and
 
-   failure of any of our significant resellers to make timely payment of our invoices.

Our dependence on a limited number of third party suppliers for raw materials, key components for our solar power products and custom-built equipment for our operations could prevent us from delivering our products to our customers within required timeframes and we may experience order cancellation and loss of market share.

We manufacture all of our solar power products using materials and components procured from a limited number of third-party suppliers. If we fail to develop or maintain our relationships with these or our other suppliers, we may be unable to manufacture our products or our products may be available only at a higher cost or after a long delay, which could prevent us from delivering our products to our customers within required time frames and we may experience order cancellation and loss of market share. We currently do not have contracts with many of our suppliers and may not be able to procure sufficient quantities of the materials and components necessary to manufacture our products on acceptable commercial terms or at all. To the extent the processes that our suppliers use to manufacture materials and components are proprietary, we may be unable to obtain comparable materials and components from alternative suppliers. The failure of a supplier to supply materials and components in a timely manner, or to supply materials and components that meet our quality, quantity and cost requirements could impair our ability to manufacture our products and/or increase their costs, particularly if we are unable to obtain substitute sources of these materials and components on a timely basis or on terms acceptable to us. In addition, our manufacturing processes utilize custom-built equipment that is currently produced by a limited number of suppliers. A supplier’s failure to supply this equipment in a timely manner, with adequate quality and on terms acceptable to us could delay our capacity expansion of our manufacturing facility and otherwise disrupt our production schedule or increase our costs of production.

Our use of forecasts to manage our inventory could result in insufficient quantities to meet reseller demand or excess inventory.

We generally do not obtain long-term contracts or purchase orders prior to the production of our solar power products. Instead, we rely on forecasts to determine the timing of our production schedules and the volume and mix of product to be manufactured. The level and timing of orders placed by our resellers may vary for many reasons. As a result, at any particular

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time, we may not have enough inventory to meet demand or we may have excess inventory, each of which could negatively impact our operating results. In addition, as we manufacture more solar power products without related purchase orders, we increase our risk of loss of revenues due to the obsolescence of products held in inventory for which we have already incurred production costs.

The success of our business depends on the continuing contributions of our key personnel and our ability to attract and retain new qualified employees in a competitive labor market.

We have attracted a highly skilled management team and specialized workforce, including scientists, engineers, researchers, and manufacturing and marketing professionals. If we were to lose the services of Richard M. Feldt, our Chief Executive Officer, President and a director, or any of our other executive officers and key employees, our business could be materially and adversely impacted. We had 151 employees as of December 31, 2003, and anticipate that we will need to hire a significant number of new highly-skilled technical, manufacturing, sales and marketing, and administrative personnel if we are to successfully develop and market our products, develop our distribution network, and operate our expanded manufacturing facility. Competition for personnel is intense, and qualified technical personnel are likely to remain a limited resource for the foreseeable future. Locating candidates with the appropriate qualifications, particularly in the desired geographic location, can be costly and difficult. We may not be able to hire the necessary personnel to implement our business strategy, or we may need to provide higher compensation or more training to our personnel than we currently anticipate. Moreover, any officer or employee can terminate his or her relationship with us at any time.

Our management team may not be able to successfully implement our business strategies because it has limited experience managing a rapidly growing company.

If our management team is unable to manage the rapid growth of our business operations, then our product development, the expansion of our manufacturing operations and distribution network, and our sales and marketing activities would be materially and adversely affected. In connection with the planned expansion of our manufacturing capacity, we have undergone and anticipate undergoing further rapid growth in the scope of our operations and the number of our employees, which is likely to place a significant strain on our senior management team and other resources. In addition, we may encounter difficulties in effectively managing the budgeting, forecasting and other process control issues presented by this rapid growth. We may seek to augment or replace members of our management team or we may lose key members of our management team, and we may not be able to attract new management talent with sufficient skill and experience.

We face intense competition from other companies producing solar power and other energy generation products. If we fail to compete effectively, we may be unable to increase our market share and sales.

The solar power market is intensely competitive and rapidly evolving. Our competitors have established a market position more prominent than ours, and if we fail to attract and retain customers and establish a successful distribution network for our solar power products, we may be unable to increase our sales and market share. There are over 20 companies in the world that produce solar power products, including BP Solar, Kyocera Corporation, Royal Dutch Shell, Sharp Corporation, RWE, and Sanyo Corporation. Other existing and potential competitors in the solar power market include universities and research institutions. We also expect that future competition will include new entrants to the solar power market offering new technological solutions. Further, many of our competitors are developing and are currently producing products based on new solar power technologies, including other crystalline silicon ribbon and sheet technologies, that they believe will ultimately have costs similar to, or lower than, our projected costs.

Most of our competitors are substantially larger than we are, have longer operating histories and have substantially greater financial, technical, manufacturing and other resources than we do. Many also have greater name recognition, a more established distribution network and a larger installed base of customers. In addition, many of our competitors have well-established relationships with our current and potential customers and have extensive knowledge of our target markets. As a result, our competitors may be able to devote greater resources to the research, development, promotion and sale of their products and respond more quickly to evolving industry standards and changing customer requirements than we can.

If we are unable to protect our intellectual property adequately, we could lose our competitive advantage in the solar power market.

Our ability to compete effectively against competing solar power technologies will depend, in part, on our ability to protect our current and future proprietary technology, product designs and manufacturing processes through a combination of patent, copyright, trademark, trade secret and unfair competition laws. We may not be able to adequately protect our intellectual property and may need to defend our intellectual property against infringement claims, either of which could result in the loss

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of our competitive advantage in the solar power market and materially harm our business and profitability. We face the following risks in protecting our intellectual property:

-   we cannot be certain that our pending United States and foreign patent applications will result in issued patents or that the claims allowed are or will be sufficiently broad to protect our technology or processes;
 
-   our license, but not our right, to practice the String Ribbon technology terminates upon expiration of the underlying patents, the first of which expired in June 2003, and our historical operating experience with String Ribbon and our related patented and proprietary manufacturing processes may not adequately protect our competitive advantage after these patents have expired;
 
-   third parties may design around our patented technologies or seek to challenge or invalidate our patented technologies;
 
-   we may incur significant costs and diversion of management resources in prosecuting or defending patent infringement suits;
 
-   we may not be successful in prosecuting or defending patent infringement suits and, as a result, may need to seek to obtain a license of the third party’s intellectual property rights; however, a license may not be available to us or may not be available to us on commercially reasonable terms; and
 
-   the contractual provisions we rely on to protect our trade secrets and proprietary information, such as our confidentiality and non-disclosure agreements with our employees, consultants and other third parties, may be breached and our trade secrets and proprietary information disclosed to the public.

Existing regulations and changes resulting from electric utility deregulation may present technical, regulatory and economic barriers to the purchase and use of solar power products, which may significantly reduce demand for our products.

The market for electricity generation products is heavily influenced by federal, state and local government regulations and policies concerning the electric utility industry, as well as internal policies and regulations promulgated by electric utilities. These regulations and policies often relate to electricity pricing and technical interconnection of customer-owned electricity generation. In the United States and in a number of other countries, these regulations and policies are being modified and may continue to be modified. Customer purchases of, or further investment in the research and development of, alternative energy sources, including solar power technology, could be deterred by these regulations and policies, which could result in a significant reduction in the potential demand for our solar power products.

We anticipate that our solar power products and their installation will be subject to oversight and regulation in accordance with national and local ordinances relating to building codes, safety, environmental protection, utility interconnection and metering and related matters. Any new government regulations or utility policies pertaining to our solar power products may result in significant additional expenses to us, our resellers and their customers and, as a result, could cause a significant reduction in demand for our solar power products.

The reduction or elimination of government subsidies and economic incentives for on-grid applications could cause our sales to decline.

We believe that the growth of some of our target markets, including the market for on-grid applications, depends in part on the availability and size of government subsidies and economic incentives. Accordingly, the reduction or elimination of government subsidies and economic incentives may adversely affect the growth of these markets, which could cause our sales to decline. Today, the cost of solar power substantially exceeds the cost of power furnished by the electric utility grid. As a result, federal, state and local governmental bodies in many countries, most notably the United States, Japan and Germany, have provided subsidies in the form of cost reductions, tax write-offs and other incentives to end users, distributors, systems integrators and manufacturers of solar power products to promote the use of solar energy in on-grid applications and to reduce dependency on other forms of energy. These government subsidies and economic incentives could be reduced or eliminated altogether.

The lack or inaccessibility of financing for off-grid solar power applications could cause our sales to decline.

One of our key markets is off-grid solar power applications to developed and developing countries. In some developing countries, government agencies and the private sector have, from time to time, provided subsidies or financing on preferred terms for rural electrification programs. We believe that the availability of financing could have a significant effect on the level

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of sales of off-grid solar power applications, particularly in developing countries where users may not have sufficient resources or credit to otherwise acquire solar power systems. If existing financing programs for off-grid solar power applications are eliminated or if financing is inaccessible, the growth of the market for off-grid applications may be adversely affected, which could cause our sales to decline.

Our reliance on government contracts to partially fund our research and development programs could impair our ability to commercialize our solar power technologies and would increase our research and development expenses.

We intend to continue our policy of selectively pursuing contract research, product development, and market development programs funded by various agencies of the United States, state and international governments to complement and enhance our own resources. The percentage of our total revenues derived from government-related contracts was approximately 17% for the year ended December 31, 2003. During 2003, we had two active research contracts with the National Institute of Standards and Technology and the National Renewable Energy Laboratory.

These government agencies may not continue their commitment to programs to which our development projects are applicable. Moreover, we may not be able to compete successfully to obtain funding through these or other programs. A reduction or discontinuance of these programs or of our participation in these programs would increase our research and development expenses, which could impair our ability to develop our solar power technologies.

In addition, contracts involving government agencies may be terminated at the convenience of the agency. Other risks include potential disclosure of our confidential information to third parties and the exercise of “march-in” rights by the government. Our government-sponsored research contracts require that we provide regular written technical updates on a monthly, quarterly or annual basis, and, at the conclusion of the research contract, a final report on the results of our technical research. Because these reports are generally available to the public, third parties may obtain some aspects of our sensitive confidential information. March-in rights refer to the right of the United States government or government agency to require us to grant a license to the technology to a responsible applicant or, if we refuse, the government may grant the license itself. The government can exercise its march-in rights if it determines that action is necessary because we fail to achieve practical application of the technology, because action is necessary to alleviate health or safety needs, or to meet requirements of federal regulations, or to give the United States industry preference. Funding from government contracts also may limit when and how we can deploy our technology developed under those contracts.

Compliance with environmental regulations can be expensive and inadvertent noncompliance may result in adverse publicity and potentially significant monetary damages and fines.

We are required to comply with all federal, state and local regulations regarding protection of the environment. If more stringent regulations are adopted in the future, the costs of compliance with these new regulations could be substantial. We believe that we have all necessary permits to conduct our business as it is presently conducted. If we fail to comply with present or future environmental regulations, however, we may be required to pay substantial fines, suspend production or cease operations. We use, generate and discharge toxic, volatile and otherwise hazardous chemicals and wastes in our research and development and manufacturing activities. Any failure by us to control the use of, or to restrict adequately the discharge of, hazardous substances could subject us to potentially significant monetary damages and fines. In addition, under some federal and state statutes and regulations, a governmental agency may seek recovery and response costs from operators of property where releases of hazardous substances have occurred or are ongoing, even if the operator was not responsible for such release or otherwise at fault.

Product liability claims against us could result in adverse publicity and potentially significant monetary damages.

Like other retailers, distributors and manufacturers of products that are used by consumers, we face an inherent risk of exposure to product liability claims in the event that the use of the solar power products we sell results in injury. Since our products are electricity producing devices, it is possible that consumers could be injured or killed by our products, whether by product malfunctions, defects, improper installation or other causes. In addition, since sales of our existing products have been modest and the products we are developing incorporate new technologies and use new installation methods, we cannot predict whether product liability claims will be brought against us in the future or the effect of any resulting adverse publicity on our business. Moreover, we may not have adequate resources in the event of a successful claim against us. We have evaluated the potential risks we face and believe that we have appropriate levels of insurance for product liability claims. We rely on our general liability insurance to cover product liability claims and have not obtained separate product liability insurance. The successful assertion of product liability claims against us could result in potentially significant monetary damages and if our insurance protection is inadequate, could require us to make significant payments.

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Risks Associated With the Market for Our Common Stock

Our officers and directors control 32% of our voting stock and may be able to significantly influence corporate actions.

As of March 17, 2004, our executive officers, directors and entities affiliated with them controlled 32% of our voting stock. As a result, these stockholders, acting together, may be able to significantly influence all matters requiring approval by our stockholders, including the election of directors, the approval of charter and by-law amendments, and the approval of mergers or other business combinations.

The price of our common stock may be volatile.

The stock market has, from time to time, experienced extreme price and trading volume fluctuations, and the market prices of technology companies such as ours have been extremely volatile. Our operating performance will significantly affect the market price of our common stock. To the extent we are unable to compete effectively and gain market share or the other factors described in this section affect us, our stock price will likely decline. The market price of our common stock also may be adversely impacted by broad market and industry fluctuations regardless of our operating performance, including general economic and technology trends. In addition, companies that have experienced volatility in the market price of their stock have been the subject of securities class action litigation. We may be involved in securities class action litigation in the future. This litigation often results in substantial costs and a diversion of management’s attention and resources.

The large number of shares eligible for public sale could cause our stock price to decline.

The market price of our common stock could decline as a result of the resale of the shares of common stock issuable upon conversion of the Series A convertible preferred stock and the exercise of the warrant issued in connection with the private placement financing or the perception that these sales could occur. These sales also might make it more difficult for us to sell equity securities in the future at a time and price that we deem appropriate.

We are subject to anti-takeover provisions in our charter and by-laws and under Delaware law that could delay or prevent an acquisition of our company, even if the acquisition would be beneficial to our stockholders.

Provisions of our certificate of incorporation, our by-laws and Delaware law could make it more difficult and expensive for a third party to pursue a tender offer, change in control transaction or takeover attempt that is opposed by our board of directors. Stockholders who wish to participate in these transactions may not have the opportunity to do so. We also have a staggered board of directors, which makes it difficult for stockholders to change the composition of our board of directors in any one year. If a tender offer, change in control transaction, takeover attempt or change in our board of directors is prevented or delayed, the market price of our common stock could decline.

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ITEM 7A. QUANTITATIVE AND QUALITATIVE DISCLOSURES ABOUT MARKET RISK:

INTEREST RATE RISK

We do not use derivative financial instruments. Interest income earned on our cash, cash equivalents and short-term investments is subject to interest rate fluctuations, but we believe that the impact of these fluctuations does not have a material effect on our financial position due to the immediate available liquidity or short-term nature of these financial instruments. For these reasons, a hypothetical 100-basis point adverse change in interest rates would not have a material effect on our consolidated financial position, results of operations or cash flows.

FOREIGN CURRENCY EXCHANGE RATE RISK

Through December 31, 2003, all of our sales were denominated in United States dollars. Accordingly, we have not been materially exposed to fluctuations in currency exchange rates with respect to our product sales. However, since we sell a significant portion of our products internationally, the relative competitiveness of our products is impacted by foreign currency exchange rates. We expect that during 2004, a substantial portion of our sales will be denominated in local currencies, which would further expose us to foreign exchange gains or losses. As we expand our manufacturing operations and distribution network internationally, our exposure to fluctuations in currency exchange rates may increase. Additionally, from time to time we may purchase equipment and materials internationally, and to the extent that such purchases are billed in foreign currency, we will be exposed to currency gains or losses.

ITEM 8. FINANCIAL STATEMENTS AND SUPPLEMENTARY DATA:

The Company’s Financial Statements and related Notes and the Report of Independent Auditors are included beginning on page F-1 of this Annual Report on Form 10-K.

ITEM 9. CHANGES IN AND DISAGREEMENTS WITH ACCOUNTANTS ON ACCOUNTING AND FINANCIAL DISCLOSURE:

None.

ITEM 9A. Controls and Procedures:

Evaluation of Disclosure Controls and Procedures

Our Chief Executive Officer and our Chief Financial Officer, after evaluating the effectiveness and design of our disclosure controls and procedures as defined in Exchange Act Rule 15d-15(e) as of the end of the period covered by this report (the “Evaluation Date”), have concluded that as of the Evaluation Date, our disclosure controls and procedures were effective, in all material respects, to ensure that information required to be disclosed in the reports that we file and submit under the Exchange Act of 1934 is recorded, processed, summarized and reported as and when required.

Internal Control Over Financial Reporting

During the period covered by this report, there have been no changes in our internal control over financial reporting that have materially affected or are reasonably likely to materially affect our internal control over financial reporting.

PART III

ITEM 10. DIRECTORS AND EXECUTIVE OFFICERS OF THE REGISTRANT:

The information required under this item may be found under the sections captioned “Election of Directors”, “Occupations of Directors and Executive Officers”, “Section 16(a) Beneficial Ownership Reporting Compliance” and “Code of Ethics” in our Proxy Statement (the “2003 Proxy Statement”), which will be filed with the Securities and Exchange Commission not later than 120 days after the close of our fiscal year ended December 31, 2003, and is incorporated herein by reference.

ITEM 11. EXECUTIVE COMPENSATION:

The information required under this item may be found under the section captioned “Compensation and Other Information Concerning Directors and Officers” in the 2003 Proxy Statement, and is incorporated herein by reference.

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ITEM 12. SECURITY OWNERSHIP OF CERTAIN BENEFICIAL OWNERS AND MANAGEMENT:

The information required under this item may be found under the section captioned “Securities Ownership of Certain Beneficial Owners and Management” in the 2003 Proxy Statement, and is incorporated herein by reference.

ITEM 13. CERTAIN RELATIONSHIPS AND RELATED TRANSACTIONS:

The information required under this item may be found under the caption “Certain Relationships and Related Transactions” in the 2003 Proxy Statement, and is incorporated herein by reference.

ITEM 14. PRINCIPAL ACCOUNTING FEES AND SERVICES:

The information required under this item may be found under the caption “[Principal Accounting Fees and Services]” in the 2003 Proxy Statement, and is incorporated herein by reference.

ITEM 15. EXHIBITS, FINANCIAL STATEMENT SCHEDULES AND REPORTS ON FORM 8-K:

     (a) The following documents are filed as part of this Annual Report on Form 10-K:

        1. Consolidated Financial Statements. The financial statements included in Item 8 of Part II which appear beginning on page 33 of this Annual Report on Form 10-K.

        2. Exhibits. The following exhibits:

     
Exhibit    
Number
  Description
3.1 (1)
  Third Amended and Restated Certificate of Incorporation of the Registrant. (Exhibit 3.2)
 
   
3.2 (1)
  Second Amended and Restated By-laws of the Registrant. (Exhibit 3.4)
 
   
4.1(2)
  Certificate of Amendment of Third Amended and Restated Certificate of Incorporation of the Registrant filed with the Secretary of State of the State of Delaware on May 15, 2003. (Exhibit 4.3)
 
   
4.2(2)
  Certificate of the Powers, Designations, Preferences and Rights of the Series A Convertible Preferred Stock of the Registrant. (Exhibit 4.4)
 
   
4.3(3)
  Form of Warrant issued to Beacon Power Corporation. (Exhibit 10.4)
 
   
10.1 (1)*
  1994 Stock Option Plan. (Exhibit 10.1)
 
   
10.2 (1)*
  2000 Stock Option and Incentive Plan. (Exhibit 10.2)
 
   
10.3 (1)*
  2000 Employee Stock Purchase Plan. (Exhibit 10.3)
 
   
10.4 (1)
  Lease Agreement between Registrant W9/TIB Real Estate Limited Partnership dated as of January 31, 2000, as amended (Exhibit 10.5)
 
   
10.5 (1)+
  Agreement between Registrant and Emanuel M. Sachs dated as of September 30, 1994, as amended. (Exhibit 10.7)
 
   
10.6 (1)
  Series D Preferred Stock Purchase Agreement dated as of December 28, 1999. (Exhibit 10.8)
 
   
10.7 (1)
  Form of Indemnification Agreement between Registrant and each of its directors and executive officers. (Exhibit 10.9)
 
   
10.8 (2)
  Stock and Warrant Purchase Agreement dated as of March 21, 2003
 
   
10.9 (2)
  Form of Registration Rights Agreement
 
   
10.10 (2)
  Voting Agreement dated as of March 21, 2003
 
   
21.1
  Subsidiaries of the Registrant. (filed herewith).
 
   
23.1
  Consent of PricewaterhouseCoopers LLP. (filed herewith)
 
   
24.1
  Power of Attorney (included on Page II-2)
 
   
31.1
  CEO Certification pursuant to Rule 13a-14(a) and Rule 15d-14(a) of the Securities Exchange Act of 1934, as adopted pursuant to Section 302 of the Sarbanes-Oxley Act of 2002 (filed herewith).
 
   
31.2
  CFO Certification pursuant to Rule 13a-14(a) and Rule 15d-14(a) of the Securities Exchange Act of 1934, as adopted pursuant to Section 302 of the Sarbanes-Oxley Act of 2002 (filed herewith).
 
   
32.1
  CEO Certification pursuant to Rule 13a-14(b) and Rule 15d-14(b) of the Securities Exchange Act of 1934, as adopted pursuant to Section 906 of the Sarbanes-Oxley Act of 2002 (filed herewith).
 
   
32.2
  CFO Certification pursuant to Rule 13a-14(b) and Rule 15d-14(b) of the Securities Exchange Act of 1934, as adopted pursuant to Section 906 of the Sarbanes-Oxley Act of 2002 (filed herewith).

+ Confidential treatment granted as to certain portions.

* Indicates a management contract or compensatory plan, contract or arrangement.

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(1)   Incorporated herein by reference to the exhibits to the Company’s Registration Statement on Form S-1, as amended (File No. 333-43140). The number given in parenthesis indicates the corresponding exhibit number in such Form S-1.
 
(2)   Incorporated herein by reference to the exhibits to the Company’s Registration Statement on Form S-8 (File No. 333-105963). The number given in parenthesis indicates the corresponding exhibit number in such Form S-8.
 
(3)   Incorporated herein by reference to the exhibits to the Company’s Registration Statement on Form S-3 (File No. 333-106126). The number given in parenthesis indicates the corresponding exhibit number in such Form S-3.
 
(4)   Incorporated herein by reference to the exhibits to the Company’s Current Report on Form 8-K filed on March 24, 2003

      (b)Reports on Form 8-K:

        During the quarter ended December 31, 2003, the Company filed a report on form 8-K dated November 5, 2003, reporting information under Item 5 relating to the press release regarding its financial results for the quarter ending September 30, 2003. The Company also filed a report on form 8-K dated December 12, 2003, reporting information under Item 5 and Item 7 relating to the press release regarding the appointment of Richard M. Feldt as the Company’s new Chief Executive Officer.

        (c)Exhibits:

     The Company hereby files as part of this Annual Report on Form 10-K the exhibits listed in Item 15(a)(3) set forth above. Exhibits which are incorporated herein by reference may be inspected and copied at the public reference facilities maintained by the SEC at the SEC’s Public Reference Room at 450 Fifth Street, N.W., Washington, D.C. 20549, and at the SEC’s regional offices located at 233 Broadway, New York, New York 10279, and at Citicorp Center, 500 West Madison Street, Suite 1400, Chicago, Illinois 60611-2511. Copies of such material may be obtained by mail from the Public Reference Section of the SEC at Judiciary Plaza, 450 Fifth Street, N.W., Washington, D.C. 20549, at prescribed rates. The public may obtain information on the operation of the Public Reference Room by calling 1-800-SEC-0330. The SEC also maintains a web site that contains reports, proxy and information statements and other information regarding registrants that file electronically with the SEC at the address “http://www.sec.gov”.

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INDEX TO FINANCIAL STATEMENTS

         
    Page
Report of Independent Auditors
    34  
Consolidated Balance Sheets as of December 31, 2002 and 2003
    35  
Consolidated Statements of Operations for the years ended December 31, 2001, 2002 and 2003
    36  
Consolidated Statements of Stockholders’ Equity for the years ended December 31, 2001, 2002 and 2003
    37  
Consolidated Statements of Cash Flows for the years ended December 31, 2001, 2002 and 2003
    38  
Notes to Financial Statements
    39  

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REPORT OF INDEPENDENT AUDITORS

To the Board of Directors and Stockholders of Evergreen Solar, Inc.

In our opinion, the accompanying consolidated balance sheets and the related consolidated statements of operations, of stockholders’ equity, and of cash flows present fairly, in all material respects, the financial position of Evergreen Solar, Inc. and its subsidiary at December 31, 2003 and 2002, and the results of their operations and their cash flows for each of the three years in the period ended December 31, 2003, in conformity with accounting principles generally accepted in the United States of America. These financial statements are the responsibility of the Company’s management; our responsibility is to express an opinion on these financial statements based on our audits. We conducted our audits of these statements in accordance with auditing standards generally accepted in the United States of America, which require that we plan and perform the audit to obtain reasonable assurance about whether the financial statements are free of material misstatement. An audit includes examining, on a test basis, evidence supporting the amounts and disclosures in the financial statements, assessing the accounting principles used and significant estimates made by management, and evaluating the overall financial statement presentation. We believe that our audits provide a reasonable basis for our opinion.

PricewaterhouseCoopers LLP

Boston, Massachusetts
February 27, 2004

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EVERGREEN SOLAR, INC.
CONSOLIDATED BALANCE SHEETS AS OF DECEMBER 31, 2002 AND 2003
(IN THOUSANDS, EXCEPT SHARE DATA)

                 
    December 31,   December 31,
    2002
  2003
Assets
               
Current assets:
               
Cash and cash equivalents
  $ 1,194     $ 4,620  
Marketable securities
    7,289       15,720  
Accounts receivable, net of allowance for doubtful accounts of $140 and $227 at December 31, 2002 and December 31, 2003, respectively
    2,848       983  
Interest receivable
    57       154  
24,039  
Restricted cash
    464       414  
Fixed assets, net
    16,905       21,523  
 
   
 
     
 
 
Total assets
  $ 31,963     $ 45,976  
 
   
 
     
 
 
Liabilities, convertible preferred stock and stockholders’ equity
               
Current liabilities:
               
Accounts payable
  $ 861     $ 905  
Accrued employee compensation
    569       425  
Accrued warranty
    326       426  
Other accrued expenses
    294       244  
 
   
 
     
 
 
Total current liabilities
    2,050       2,000  
Convertible preferred stock:
               
Series A, $0.01 par value, 0 and 26,227,668 shares authorized, 0 and 22,679,125 issued and outstanding at December 31, 2002 and December 31, 2003, respectively (stated at liquidation value)
          27,032  
Stockholders’ equity:
               
Common stock, $0.01 par value, 30,000,000 and 70,000,000 shares authorized, 11,410,826 and 15,126,268 issued and outstanding at December 31, 2002 and December 31, 2003, respectively
    114       151  
Additional paid-in capital
    71,508       73,239  
Deferred compensation
    (360 )     (89 )
Accumulated deficit
    (41,356 )     (56,330 )
Accumulated other comprehensive income (loss)
    7       (27 )
 
   
 
     
 
 
Total stockholders’ equity
    29,913       16,944  
 
   
 
     
 
 
Total liabilities, convertible preferred stock and stockholders’ equity
  $ 31,963     $ 45,976  
 
   
 
     
 
 

The accompanying notes are an integral part of these consolidated financial statements.

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EVERGREEN SOLAR, INC.
CONSOLIDATED STATEMENTS OF OPERATIONS
(IN THOUSANDS, EXCEPT PER SHARE DATA)

                         
    For the Years Ended December 31,
    2001
  2002
  2003
Revenues:
                       
Product revenues
  $ 1,546     $ 5,296     $ 7,746  
Research revenues
    932       1,448       1,565  
 
   
 
     
 
     
 
 
Total revenues
    2,478       6,744       9,311  
 
   
 
     
 
     
 
 
Operating expenses:
                       
Cost of product revenues
    9,649       12,405       15,379  
Research and development expenses, including costs of research revenues
    3,063       3,692       3,791  
Selling, general and administrative expenses
    4,088       4,520       5,337  
 
   
 
     
 
     
 
 
Total operating expenses
    16,800       20,617       24,507  
 
   
 
     
 
     
 
 
Operating loss
    (14,322 )     (13,873 )     (15,196 )
Interest income, net
    1,845       674       222  
 
   
 
     
 
     
 
 
Net loss
    (12,477 )     (13,199 )     (14,974 )
Accretion and dividends on Series A convertible preferred stock
                (13,498 )
 
   
 
     
 
     
 
 
Net loss attributable to common stockholders
    (12,477 )     (13,199 )     (28,472 )
Other comprehensive income (loss):
                       
Unrealized gain (loss) on marketable securities
    249       (242 )     (34 )
 
   
 
     
 
     
 
 
Comprehensive loss
  $ (12,228 )   $ (13,441 )   $ (28,506 )
 
   
 
     
 
     
 
 
Net loss per share attributable to common stockholders (basic and diluted)
  $ (1.10 )   $ (1.16 )   $ (2.39 )
Weighted average shares used in computing basic and diluted net loss per share attributable to common stockholders
    11,304       11,405       11,899  

The accompanying notes are an integral part of these consolidated financial statements.

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EVERGREEN SOLAR, INC.
CONSOLIDATED STATEMENTS OF STOCKHOLDERS’ EQUITY
(IN THOUSANDS)

                                                         
     Common Stock
Additional
Paid-In
    Deferred       Accumulated     Accumulated
Other
Comprehensive
  Total
Stockholders’
    Shares
  Amount
  Capital
  Compensation
  Deficit
  Income (loss)
  Equity
Balance at December 31, 2000
    11,170     $ 111     $ 70,671     $ (959 )   $ (15,680 )   $     $ 54,143  
Issuance of common stock pursuant to exercise of options
    20       1       11                               12  
Issuance of common stock pursuant to exercise of warrants
    209       2       798                               800  
Compensation expense associated with stock options
                    37       290                       327  
Terminated options
                    (20 )     20                        
Other comprehensive income
                                            249       249  
Net loss
                                    (12,477 )             (12,477 )
 
   
 
     
 
     
 
     
 
     
 
     
 
     
 
 
Balance at December 31, 2001
    11,399     $ 114     $ 71,497     $ (649 )   $ (28,157 )   $ 249     $ 43,054  
Issuance of common stock pursuant to exercise of options
    12             11                               11  
Compensation expense associated with stock options
                            289                       289  
Other comprehensive loss
                                            (242 )     (242 )
Net loss
                                    (13,199 )             (13,199 )
 
   
 
     
 
     
 
     
 
     
 
     
 
     
 
 
Balance at December 31, 2002
    11,411     $ 114     $ 71,508     $ (360 )   $ (41,356 )   $ 7     $ 29,913  
Issuance of common stock pursuant to exercise of options
    5             8                               8  
Shares of common stock issued under ESPP
    3             2                               2  
Conversion of Series A convertible preferred stock to common stock
    3,707       37       4,116                               4,153  
Compensation expense associated with stock options
                    80       271                       351  
Accretion of Series A convertible preferred stock
                    (11,688 )                             (11,688 )
Beneficial conversion feature of Series A convertible preferred stock
                    10,314                               10,314  
Dividend on Series A convertible preferred stock
                    (1,810 )                             (1,810 )
Issuance of warrants in connection with Series A convertible preferred stock
                    625                               625  
Reversal of overaccrued IPO financing costs
                    84                               84  
Other comprehensive loss
                                            (34 )     (34 )
Net loss
                                    (14,974 )             (14,974 )
 
   
 
     
 
     
 
     
 
     
 
     
 
     
 
 
Balance at December 31, 2003
    15,126     $ 151     $ 73,239     $ (89 )   $ (56,330 )   $ (27 )   $ 16,944  
 
   
 
     
 
     
 
     
 
     
 
     
 
     
 
 

The accompanying notes are an integral part of these consolidated financial statements.

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EVERGREEN SOLAR, INC.
CONSOLIDATED STATEMENTS OF CASH FLOWS
(IN THOUSANDS)

                         
    2001
  2002
  2003
Cash flows from operating activities:
                       
Net loss
  $ (12,477 )   $ (13,199 )   $ (14,974 )
Adjustments to reconcile net loss to net cash used in operating activities:
                       
Depreciation expense
    1,003       1,968       2,005  
Bad debt expense
          127       87  
Amortization of bond premiums
          331       381  
Write-off of fixed assets
          43       513  
Issuance of stock options to consultants
    37             80  
Compensation expense associated with employee stock options
    290       289       271  
Changes in operating assets and liabilites:
                       
Inventory
    (591 )     (1,195 )     175  
Interest receivable
    (189 )     332       (97 )
Accounts receivable
    461       (2,487 )     1,778  
Other current assets
    (113 )     (754 )     469  
Accounts payable
    197       3       44  
Accrued expenses
    (31 )     241       (94 )
 
   
 
     
 
     
 
 
Net cash used in operating activities
    (11,413 )     (14,301 )     (9,362 )
 
   
 
     
 
     
 
 
Cash flows from investing activities:
                       
Purchases of fixed assets
    (9,380 )     (2,916 )     (7,136 )
Restricted cash
                50  
Purchases of marketable securities
    (87,041 )     (10,762 )     (26,850 )
Proceeds from sale and maturity of marketable securities
    96,405       26,609       18,088  
 
   
 
     
 
     
 
 
Net cash provided by (used in) investing activites
    (16 )     12,931       (15,848 )
 
   
 
     
 
     
 
 
Cash flows from financing activities:
                       
Issuance of Series A convertible preferred stock
                29,375  
Financing costs on issuance of Series A convertible preferred stock
                (849 )
Proceeds from issuance of common stock warrant
                100  
Proceeds from exercise of stock options and shares purchased under Employee Stock Purchase Plan
    812       10       10  
 
   
 
     
 
     
 
 
Net cash flow provided by financing activities
    812       10       28,636  
 
   
 
     
 
     
 
 
Net increase (decrease) in cash and cash equivalents
    (10,617 )     (1,360 )     3,426  
Cash and cash equivalents at beginning of period
    13,171       2,554       1,194  
 
   
 
     
 
     
 
 
Cash and cash equivalents at end of period
  $ 2,554     $ 1,194     $ 4,620  
 
   
 
     
 
     
 
 
Supplemental cash flow information:
                       
Taxes paid
    50       32       36  
Realized gains on sale of marketable securities
                16  
Non-cash Series A convertible preferred stock dividends earned
                1,810  
Non-cash conversion of Series A convertible preferred stock to common
                4,153  

The accompanying notes are an integral part of these consolidated financial statements.

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EVERGREEN SOLAR, INC.
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

1.   NATURE OF BUSINESS
 
    Evergreen Solar, Inc. (the “Company”), incorporated in August 1994, develops, manufactures and markets solar power products, including solar cells, panels and systems. In April 1997 the Company commenced product sales. The Company has incurred losses since inception and has an accumulated deficit, which has been funded by issuing debt and equity securities
 
    The Company has historically financed operations and met capital expenditures requirements primarily through sales of capital stock and, to a lesser extent, research and product revenues. The first of the Marlboro facility’s two manufacturing lines became operational in 2001. As more fully described in Note 6 “Capital Stock,” on May 15, 2003, the Company consummated the private placement transaction contemplated by the purchase agreement entered into on March 21, 2003 with certain investors to raise $29.5 million through the issuance of 26,227,668 shares of Series A convertible preferred stock and the sale of a warrant to purchase 2,400,000 shares of common stock. The proceeds to the Company, net of financing expenses of approximately $849,000, were approximately $28.6 million. The Company expects to use the net proceeds from this transaction to fund the construction of the second manufacturing line and other operations of the Company.
 
    The Company needs additional financing to execute its business plan and to respond to business contingencies such as the need to enhance its operating infrastructure, respond to competitive pressures and acquire complementary businesses or necessary technologies. For example, in addition to capital commitments as of December 31, 2003, substantial further capital expenditures will be required over the next twelve months to increase the capacity at the Company’s manufacturing facility to its target level of 10 to 14 megawatts for both manufacturing lines. The Company does not know whether it will be able to raise additional financing on favorable financing terms. If adequate funds are not available or are not available on acceptable terms, the Company’s ability to fund its operations, develop and expand its manufacturing operations and distribution network, or otherwise respond to competitive pressures would be significantly limited. In such a situation, the Company would need to implement fundamental changes to its business and operations which would likely include substantially reducing, suspending, or terminating the Company’s capacity expansion and substantially reducing daily operating expenditures from current levels, in which case the Company believes its cash, cash equivalents and short-term investments will then be sufficient to fund operations through the end of fiscal year 2004.
 
    The Company is subject to risks common to companies in the high technology and energy industries including, but not limited to, development by the Company or its competitors of new technological innovations, dependence on key personnel, protection of proprietary technology and compliance with government regulations. Any delay in the Company’s plan to scale up to full capacity may result in increased costs and could impair business operations.
 
2.   SUMMARY OF SIGNIFICANT ACCOUNTING POLICIES
 
    A summary of the major accounting policies followed by the Company in the preparation of the accompanying financial statements is set forth below.
 
    BASIS OF PRESENTATION
 
    The consolidated financial statements include the accounts of the Company’s wholly owned subsidiary, Evergreen Solar Securities, Inc. All material intercompany accounts and transactions have been eliminated.
 
    CASH AND INVESTMENTS
 
    Cash and cash equivalents consist of cash and highly liquid investments with maturities of three months or less from the date of purchase and whose carrying amount approximates fair value.
 
    The Company’s investments are classified as available-for-sale. At December 31, 2002 and 2003 the Company held US government agency bonds, treasury notes, municipal bonds, corporate bonds and commercial paper. The investments generally mature within one year from the date of purchase and are carried at market value. During 2003, there were realized gains of $18,000. At December 31, 2003, there were unrealized losses of $27,000, which are reported as part of stockholders’ equity.

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CONCENTRATION OF CREDIT RISK AND SIGNIFICANT CUSTOMERS

Financial instruments that potentially subject the Company to significant concentrations of credit risk consist principally of cash and cash equivalents, investments and accounts receivable. The Company places its cash and cash equivalents with a high quality financial institution. With respect to accounts receivable, such receivables are primarily from distributors and integrators in the solar power industry located in the United States and throughout the world. The Company performs ongoing credit evaluations of its customers ´ financial conditions. The Company does not require collateral or other security against accounts receivable; however, it maintains reserves for potential credit losses and such losses have historically been within management’s expectations. One individual customer accounted for approximately 26% of total accounts receivable as at December 31, 2003, and another customer accounted for approximately 67% and 46% of total accounts receivable as at December 31, 2002 and 2001, respectively. The Company’s five largest individual customers accounted for 76%, 85% and 85% of total accounts receivable at December 31, 2003, 2002, and 2001, respectively. Separately, one individual customer accounted for approximately 47%, 57% and 8% of product revenue for the years ended December 31, 2003, 2002 and 2001, respectively. The Company’s five largest individual customers accounted for 74%, 80% and 94% of product revenue in 2003, 2002, and 2001, respectively.

INVENTORY

Inventory is stated at the lower of cost (determined on a first-in, first-out basis) or market. Certain factors may impact the realizable value of the Company’s inventory including, but not limited to, technological changes, market demand, changes in product mix strategy, new product introductions and significant changes to its cost structure. Given the Company’s current production levels and the market value of its products, the Company currently sells its finished goods inventory at prices that are below the sum of its fixed and variable costs per unit. Accordingly, the Company writes down its finished goods inventory to realizable value equal to the difference between the cost of inventory and the estimated market value. In addition, estimates of reserves are made for obsolescence based on the current product mix on hand and its expected net realizability. If actual market conditions are less favorable or other factors arise that are significantly different than those anticipated by management, additional inventory write-downs or increases in obsolescence reserves may be required. The Company treats lower of cost or market adjustments and inventory reserves as an adjustment to the cost basis of the underlying inventory. Accordingly, favorable changes in market conditions are not recorded to inventory in subsequent periods.

GUARANTOR ARRANGEMENTS

In November 2002, the FASB issued FIN No. 45 “Guarantor’s Accounting and Disclosure Requirements for Guarantees, Including Indirect Guarantees of Indebtedness of Others, an interpretation of FASB Statements No. 5, 57, and 107 and rescission of FASB Interpretation No. 34.” The Interpretation requires that a guarantor recognize, at the inception of a guarantee, a liability for the fair value of the obligation undertaken by issuing the guarantee. The Interpretation also requires additional disclosures to be made by a guarantor in its interim and annual financial statements about its obligations under certain guarantees it has issued. The accounting requirements for the initial recognition of guarantees are applicable on a prospective basis for guarantees issued or modified after December 31, 2002. The following is a summary of the Company’s agreements that we have determined are within the scope of FIN No. 45.

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Product warranty

The Company provides for the estimated cost of product warranties at the time revenue is recognized. Given the Company’s limited operating history, historical industry solar panel failure rates are used as the basis for the warranty provision calculation. While the Company engages in product quality programs and processes, including monitoring and evaluating the quality of component suppliers, its warranty obligation is affected by product failure rates and material usage and service delivery costs incurred in correcting a product failure. If the Company’s actual product failure rates, material usage or service delivery costs differ from estimates, revisions to the estimated warranty liability would be required. Since the Company has a limited operating history and its manufacturing process differs from industry standards, its experience may be different from the industry data used as a basis for its estimate. While the Company’s methodology takes into account these uncertainties, adjustments in future periods may be required as its products mature. The following table summarizes the activity regarding the Company’s warranty accrual:

         
Balance at December 31, 2001
  $ 138,000  
Accruals for warranties issued during the period
    188,000  
Balance at December 31, 2002
  $ 326,000  
Accruals for warranties issued during the period
    100,000  
 
   
 
 
Balance at December 31, 2003
  $ 426,000  
 
   
 
 

Indemnification agreements

The Company enters into standard indemnification agreements in its ordinary course of business. Pursuant to these agreements, the Company indemnifies, holds harmless, and agrees to reimburse the indemnified party for losses suffered or incurred by the indemnified party, generally our business partners, customers, directors and officers. The term of these indemnification agreements is generally perpetual any time after execution of the agreement. The maximum potential amount of future payments the Company could be required to make under these indemnification agreements is unlimited. However, the Company has never incurred costs to defend lawsuits or settle claims related to these indemnification agreements. Furthermore, the Company has a Director and Officer insurance policy that limits its exposure with indemnification agreements specifically with its directors and officers, which enables the Company to recover a portion of any future amounts paid. As a result of the Company’s insurance policy coverage, the Company believes the estimated fair value of these indemnification agreements is minimal. The Company believes the estimated fair value of agreements with parties other than its directors and officers is minimal as well. The Company agreed to indemnify, defend and hold harmless each of the purchasers participating in the Company’s Series A convertible preferred stock financing transaction, their affiliates and their respective officers, directors, agents, employees, subsidiaries, partners, members and controlling persons to the fullest extent permitted by law from and against any and all losses, claims or written threats thereof, damages, expenses (including reasonable fees, disbursements and other charges of counsel) resulting from or arising out of the Company’s breach of any representation or warranty, covenant or agreement in the purchase agreement. The Company believes the estimated fair value of this indemnification agreement is minimal.

FIXED ASSETS

Fixed assets are recorded at cost. Provisions for depreciation are based on their estimated useful lives using the straight-line method over three to seven years for all laboratory and manufacturing equipment, computers, and office equipment. Leasehold improvements are depreciated over the shorter of the remainder of the lease’s term or the life of the improvements. Upon retirement or disposal, the cost of the asset disposed of and the related accumulated depreciation are removed from the accounts and any gain or loss is reflected in income. Expenditures for repairs and maintenance are expensed as incurred.

IMPAIRMENT OF LONG-LIVED ASSETS

The Company’s policy regarding long-lived assets is to evaluate the recoverability or usefulness of these assets when the facts and circumstances suggest that these assets may be impaired. This analysis relies on a number of factors, including changes in strategic direction, business plans, regulatory developments, economic and budget projections, technological improvements, and operating results. The test of recoverability or usefulness is a comparison of the asset value to the undiscounted cash flow of its expected cumulative net operating cash flow over the asset’s remaining useful life. If such a test indicates that impairment is required, then the asset is written down to its estimated fair value. Any write-downs would be treated as permanent reductions in the carrying amounts of the assets and an operating loss would be recognized. To date, the Company has had recurring operating losses and the recoverability of its long-lived assets is contingent upon executing

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its business plan that includes further reducing it’s manufacturing costs and significantly increasing sales. If the Company is unable to execute its business plan, the Company may be required to write down the value of its long-lived assets in future periods. No impairments were required to be recognized during the years ended December 31, 2003, 2002 and 2001.

REVENUE RECOGNITION

The Company recognizes revenue if persuasive evidence of an arrangement exists, shipment has occurred, risk of loss has transferred to the customer, sales price is fixed or determinable, and collectibility is reasonably assured. The market for solar power products is emerging and rapidly evolving. The Company currently sells its solar power products primarily to distributors, system integrators and other value-added resellers within and outside of North America, which typically resell its products to end users throughout the world. For new customers requesting credit, the Company evaluates creditworthiness based on credit applications, feedback from provided references, and credit reports from independent agencies. For existing customers, the Company evaluates creditworthiness based on payment history and known changes in their financial condition.

The Company also evaluates the facts and circumstances related to each sales transaction and considers whether risk of loss has passed to the customer upon shipment. The Company considers whether its customer is purchasing its product for stock, and whether contractual or implied rights to return the product exist or whether its customer has an end user contractually committed. The Company does not offer rights to return its product other than for normal warranty conditions and has had no history of product returns.

At the time revenue is recognized, the Company provides for the estimated cost of product warranties.

Revenue from research grants is recognized as services are rendered to the extent of allowable costs incurred. While the Company’s accounting for research contract costs are subject to audit by the sponsoring agency, in the opinion of management, no material adjustments are expected as a result of such audits.

RESEARCH AND DEVELOPMENT

All research and development costs are expensed as incurred.

INCOME TAXES

The Company accounts for income taxes under the liability method, which requires recognition of deferred tax assets, subject to valuation allowances, and liabilities for the expected future tax consequences of events that have been included in the financial statements or tax returns. Deferred income taxes reflect the net tax effects of temporary differences between the carrying amounts of assets and liabilities for financial reporting and income tax purposes. A valuation allowance is established if it is more likely than not that all or a portion of the net deferred tax assets will not be realized.

COMPREHENSIVE INCOME

Comprehensive income consists of unrealized gains and losses on available-for-sale securities. As of December 31, 2003, accumulated other comprehensive loss was $27,000, and as of December 31, 2002, accumulated other comprehensive income was $7,000. Other comprehensive income (loss) is reflected in the Company’s Consolidated Statement of Operations and the Consolidated Statement of Stockholder’s Equity.

STOCK-BASED COMPENSATION

The Company applies the accounting provisions of Accounting Principles Board (“APB”) Opinion 25 and related interpretations and has elected the disclosure-only alternative permitted under Statement of Financial Accounting Standards Board (“SFAS”) No. 123, Accounting for Stock-Based Compensation. The Company has disclosed herein pro forma net income (loss) in the footnotes using the fair value based method. All stock-based awards to non-employees are accounted for at their fair market value, as calculated using the Black-Scholes model in accordance with SFAS No. 123.

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Had compensation expense for the employee stock option plan been determined based on the fair value at the grant dates for options granted under the plan consistent with the method of SFAS 123, the net loss would have been as follows (in thousands, except per share data):

                                                 
    2001
  2002
  2003
    Net Loss   Net Loss   Net Loss   Net Loss   Net Loss   Net Loss
    Attributable   Per   Attributable   Per   Attributable   Per
    To Common   Common   To Common   Common   To Common   Common
    Stockholders
  Share
  Stockholders
  Share
  Stockholders
  Share
Net loss attributable to common stockholders, as reported
  $ (12,477 )   $ (1.10 )   $ (13,199 )   $ (1.16 )   $ (28,472 )   $ (2.39 )
Add: Stock-based employee compensation expense included in reported results
    290       0.03       289       0.03       271       0.02  
Deduct: Total stock-based employee compensation expense determined under the fair value-based method for all awards
    (1,283 )     (0.12 )     (1,177 )     (0.10 )     (1,561 )     (0.13 )
 
   
 
     
 
     
 
     
 
     
 
     
 
 
Pro forma net loss attributable to common stockholders
  $ (13,470 )   $ (1.19 )   $ (14,087 )   $ (1.23 )   $ (29,762 )   $ (2.50 )
 
   
 
     
 
     
 
     
 
     
 
     
 
 

The fair value of employee options at the date of grant were estimated using the Black-Scholes option pricing model with the following assumptions for the years ended December 31, 2001, 2002 and 2003:

                         
    2001
  2002
  2003
Expected options term
    7       7       7  
Risk-free interest rate
    4.0 %     4.0 %     4.0 %
Expected dividend yield
  None   None   None
Volatility
    90 %     90 %     90 %

Through December 31, 2000, the Company accumulated deferred compensation of $1.3 million related to stock option grants to employees. The deferred compensation represents differences between the estimated fair value of common stock on the date of grant and the exercise price. The deferred compensation is being amortized and charged to operations over the vesting period of the related options.

NET LOSS PER COMMON SHARE

The Company computes net loss per common share by dividing net loss attributable to common stockholders by the weighted average number of common shares outstanding. The calculation of diluted net loss per common share for the years ended December 31, 2001, 2002 and 2003 does not include 1,525,246, 1,146,378 and 27,526,462 potential shares of common stock equivalents outstanding at December 31, 2001, 2002 and 2003, respectively, as their inclusion would be antidilutive. Common stock equivalents include outstanding common stock options, common stock warrants and Series A convertible preferred stock.

SEGMENT REPORTING

The Company operates in a single segment: the sale of solar panels that generate electricity. The Company has no organizational structure dictated by product lines, geography or customer type. Major customer and geographic area revenue disclosures are presented in Note 12.

USE OF ESTIMATES

The preparation of financial statements in conformity with generally accepted accounting principals requires management to make estimates and assumptions that affect the reported amounts of assets and liabilities, disclosure of contingent assets and liabilities at the date of the financial statements and the reported amounts of revenue and expenses during the reporting period. Actual results could differ from those estimates. The Company bases its estimates on historical experience and various other factors believed to be reasonable under the circumstances, the results of which form the basis for making judgments about the carrying value of assets and liabilities that are not readily apparent from other sources. Estimates are used when accounting for the collectibility of receivables, realizability of finished goods inventory, estimated warranty costs, and deferred tax assets. Some of these estimates can be subjective and complex and, consequently, actual results may differ from these estimates under different assumptions or conditions. While for any given estimate or assumption made by the Company’s management there may be other estimates or assumptions that are reasonable, the Company believes that, given

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the current facts and circumstances, it is unlikely that applying any such other reasonable estimate or assumption would materially impact the financial statements.

FAIR VALUE OF FINANCIAL INSTRUMENTS

Financial instruments, including cash equivalents, accounts receivable and accounts payable are carried in the consolidated financial statements at amounts that approximate fair values at December 31, 2002 and 2003. Fair values are based on market prices and assumptions concerning the amount and timing of estimated future cash flows and assumed discount rates, reflecting varying degrees of perceived risk.

RECENT PRONOUNCEMENTS

In November 2002, the FASB issued Emerging Issues Task Force 00-21 (“EITF 00-21”), “Accounting for Revenue Arrangements with Multiple Deliverables.” EITF 00-21 requires revenue arrangements with multiple deliverables to be divided into separate units of accounting. If the deliverables in the arrangement meet certain criteria, arrangement consideration should be allocated among the separate units of accounting based on their relative fair values. Applicable revenue recognition criteria are to be considered separately for separate units of accounting. The guidance in EITF 00-21 was effective for revenue arrangements entered into in fiscal periods beginning after June 15, 2003. The adoption of EITF 00-21 did not have a material impact on the Company’s financial position or results of operations.

In January 2003, the FASB issued Interpretation (“FIN”) No. 46, “Consolidation of Variable Interest Entities” (“FIN 46”) and, in December 2003, issued a revision to that interpretation (“FIN 46R”). FIN 46R replaces FIN 46 and addresses consolidation by business enterprises of variable interest entities that possess certain characteristics. A variable interest entity (“VIE”) is defined as (a) an ownership, contractual or monetary interest in an entity where the ability to influence financial decisions is not proportional to the investment interest, or (b) an entity lacking the invested capital sufficient to fund future activities without the support of a third party. FIN 46R establishes standards for determining under what circumstances VIEs should be consolidated with their primary beneficiary, including those to which the usual condition for consolidation does not apply. The adoption of FIN 46R did not have a material impact on the Company’s financial position or results of operations.

On December 17, 2003, the Staff of the Securities and Exchange Commission (“SEC”) issued Staff Accounting Bulletin No. 104 (SAB 104), “Revenue Recognition”, which supersedes SAB 101, “Revenue Recognition in Financial Statements.” SAB 104’s primary purpose is to rescind the accounting guidance contained in SAB 101 related to multiple-element revenue arrangements that was superseded as a result of the issuance of EITF 00-21, “Accounting for Revenue Arrangements with Multiple Deliverables.” Additionally, SAB 104 rescinds the SEC’s related “Revenue Recognition in Financial Statements Frequently Asked Questions and Answers” issued with SAB 101 that had been codified in SEC Topic 13, “Revenue Recognition.” While the wording of SAB 104 has changed to reflect the issuance of EITF 00-21, the revenue recognition principles of SAB 101 remain largely unchanged by the issuance of SAB 104, which was effective upon issuance. The adoption of SAB 104 did not have a material effect on the Company’s financial position or results of operations.

3. INVENTORY

Inventory consisted of the following at December 31, 2002 and 2003 (in thousands):

                 
    December 31,   December 31,
    2002
  2003
Raw materials
  $ 1,236     $ 1,318  
Work-in-process
    148       4  
Finished goods
    810       697  
 
   
 
     
 
 
 
  $ 2,194     $ 2,019  
 
   
 
     
 
 

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4. FIXED ASSETS

Fixed assets consisted of the following at December 31, 2002 and 2003 (in thousands):

                         
    Useful   December 31,
    Life
  2002
  2003
Laboratory and manufacturing equipment
  3-7 years   $ 10,997     $ 13,542  
Computer and office equipment
  3-7 years     245       280  
Leasehold improvements
  Lesser of 15 to 20
years or lease term
    6,273       6,273  
Assets under construction
            2,769       6,812  
 
           
 
     
 
 
 
            20,284       26,907  
Less accumulated depreciation
            (3,379 )     (5,384 )
 
           
 
     
 
 
 
          $ 16,905     $ 21,523  
 
           
 
     
 
 

Depreciation expense for the years ended December 31, 2001, 2002 and 2003 was $1.0 million, $2.0 million and $2.0 million, respectively. During 2003, the Company disposed of assets that were no longer in service that had a cost of $718,340 and associated accumulated depreciation of $205,239. These assets were associated with the Company’s single ribbon furnace technology, which were retrofitted to accommodate the Company’s double ribbon furnace technology. The asset disposal resulted in a loss of $513,101 to operations. As of December 31, 2003, the Company had outstanding commitments for capital expenditures of approximately $3.0 million.

5. INCOME TAXES

Income taxes computed using the federal statutory income tax rate differ from the Company’s effective tax rate primarily due to the following for the years ended December 31, 2001, 2002 and 2003:

                         
    2001
  2002
  2003
Income tax benefit at US federal statutory tax rate
  $ (4,242,000 )   $ (4,488,000 )   $ (5,091,000 )
State income taxes, net of federal tax effect
    (786,000 )     (661,000 )     (758,000 )
Permanent items
    101,000       102,000       95,000  
Other
    (78,000 )     (52,000 )     (3,000 )
Change in deferred tax asset valuation allowance
    5,005,000       5,099,000       5,757,000  
 
   
 
     
 
     
 
 
 
  $     $     $  
 
   
 
     
 
     
 
 

As of December 31, 2003, we had federal and state net operating loss carryforwards totaling approximately $47.9 million and $39.9 million, respectively, available to reduce future taxable income and tax liabilities which expire at various dates between 2004 and 2023. In addition, as of December 31, 2003 we had federal and state research and development tax credit carryforwards of approximately $804,000 and $433,000, respectively, available to reduce future taxable income and tax liabilities which expire at various dates between 2009 and 2023. Under provisions of the Internal Revenue Code, substantial changes in our ownership may limit the amount of net operating loss carryforwards and research and development credit carryforwards, which can be used in future years. Management of the Company has evaluated the positive and negative evidence bearing upon the realizability of its deferred tax assets. Management has considered the Company’s history of losses and, in accordance with the applicable accounting standards, has fully reserved the deferred tax asset.

Deferred tax assets consist of the following at December 31, 2002 and 2003:

                 
    2002
  2003
Gross deferred tax assets
               
Net operating loss carryforwards
  $ 13,796,000     $ 18,793,000  
Research and develppment credit carryforwards
    1,036,000       1,090,000  
Capitalized R&D expenses
    2,364,000       3,114,000  
Accrued expenses and deferred compensation
    604,000       620,000  
Other
    199,000       281,000  
 
   
 
     
 
 
Total gross deferred tax assets
    17,999,000       23,898,000  
Gross deferred tax liabilities
               
Depreciation
    (847,000 )     (990,000 )
Deferred tax valuation allowance
    (17,152,000 )     (22,908,000 )
 
   
 
     
 
 
Net deferred tax asset
  $     $  
 
   
 
     
 
 

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6. CAPITAL STOCK

The Company has two classes of capital stock: common and preferred. In May 2003, the Company increased the number of authorized shares of common stock to 70,000,000. At December 31, 2003, there were 2,859,771 shares of common stock reserved for grant under both the Company’s 1994 Stock Option Plan and the Company’s 2000 Stock Option and Incentive Plan. At December 31, 2003, 7,650,000 shares of common stock were authorized for issuance under the Company’s 2000 Stock Option Plan and 40,000,000 shares were reserved for issuance upon conversion of Series A convertible preferred stock sold to several purchasers and upon exercise of a warrant issued to Beacon Power Corporation.

In May 2003, the Company increased the number of authorized shares of preferred stock to 27,227,668, of which 26,227,668 shares were designated Series A convertible preferred stock. On May 15, 2003, the Company consummated the transaction contemplated by a Stock and Warrant Purchase Agreement which was entered into on March 21, 2003 with Perseus 2000, L.L.C., Nth Power Technologies Fund II, LP, Nth Power Technologies Fund II-A, LP, RockPort Capital Partners, L.P., RP Co-Investment Fund, I, Micro-Generation Technology Fund, LLC, UVCC Fund II, UVCC II Parallel Fund, L.P., Caisse de depot et placement du Quebec, CDP Capital - Technology Ventures U.S. Fund 2002 L.P., Beacon Power Corporation, Massachusetts Technology Park Corporation, Zero Stage Capital VII, L.P., Zero Stage Capital (Cayman) VII, L.P., Zero Stage Capital SBIC VII, L.P., IMPAX Environmental Markets plc, Merrill Lynch New Energy Technology Plc, MLIIF New Energy Fund, PNE Invest Limited, Odyssey Fund, SAM Private Equity Energy Fund LP, SAM Sustainability Private Equity LP and SAM Smart Energy. As a result of the consummation of this transaction, the Company issued 26,227,668 shares of Series A convertible preferred stock at a per share purchase price of $1.12. Additionally, Beacon Power Corporation purchased a warrant to purchase 2,400,000 shares of common stock at a per share exercise price equal to $3.37, for $100,000. A total of $29.5 million was raised as a result of the consummation of the transaction. The proceeds to the Company, net of financing expenses of approximately $849,000, were approximately $28.6 million for the transaction. The shares of Series A convertible preferred stock were initially convertible into shares of common stock on a 1-to-1 basis which is subject to adjustment to account for the payment of dividends, to take into account certain changes to the Company’s capital structure and to account for future dilutive issuances. As a condition to the obligation of the purchasers to consummate the financing transaction, the Company agreed to register for resale the shares of common stock issuable upon the conversion of the Series A convertible preferred stock and the exercise of the warrant.

As a result of the preferred stock financing, accretion and dividends of $13.5 million were recorded through December 31, 2003. $11.7 million of this charge relates to accretion that was recognized immediately (during the second quarter of 2003) because the holders of shares of the Series A convertible preferred stock are entitled to convert their shares into common stock at any time. The sources of the discounts on issuance requiring this accretion charge are summarized in the following table:

         
Beneficial conversion feature
  $ 10,314,000  
Proceeds allocated to the fair value of common stock warrant
    525,000  
Financing costs
    849,000  
 
   
 
 
Total preferred stock accretion and dividends
  $ 11,688,000  
 
   
 
 

The difference between the issuance price of the Series A convertible preferred stock and the fair value of the Company’s common stock on the date of issuance of the Series A convertible preferred stock resulted in a beneficial conversion feature totaling approximately $10.3 million, which was calculated in accordance with EITF 00-27, Application of Issue No. 98-5 to Certain Convertible Instruments.

Liquidation Preference of Series A Convertible Preferred Stock

In the event of voluntary or involuntary liquidation under applicable bankruptcy or reorganization legislation, dissolution or winding up, the holders of shares of Series A convertible preferred stock will be paid in cash for each share of Series A convertible preferred stock held thereby, out of the Company’s assets legally available for distribution to stockholders, before any payment or distribution is made to any other class or series of the Company’s capital stock, an amount equal to the greater of (i) the sum of (x) the Accreted Value of each share of Series A convertible preferred stock as of such date, plus (y) all dividends accrued since the previous Compounding Date, or (ii) the aggregate amount then payable with respect to the number of shares of common stock into which such share of Series A convertible preferred stock is convertible immediately prior to such liquidation event. The liquidation preference of the Series A convertible preferred stock initially was the purchase price per share paid by the purchasers for the Series A convertible preferred stock of $1.12, subject to adjustment. The liquidation preference of the Series A convertible preferred stock was $1.19 per share as of December 31, 2003.

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In the event of the merger, consolidation or sale of all or substantially all of the Company’s assets or in the event of certain other change of control transactions, the holders of shares of Series A convertible preferred stock will be paid for each share of Series A convertible preferred stock held thereby, before any payment or distribution is made to any other class or series of our capital stock, an amount equal to the greater of (i) the sum of the Accreted Value of each share of Series A convertible preferred stock as of such date, plus all dividends accrued since the previous Compounding Date, or (ii) the aggregate amount payable in the applicable change of control transaction with respect to the number of shares of our common stock into which a share of Series A convertible preferred stock is convertible immediately prior to the consummation of the change of control transaction. If the assets available for distribution to the holders of shares of Series A convertible preferred stock are insufficient to permit payment in full to the holders thereof of the amount described above, then all of the assets available for distribution to holders of shares of Series A convertible preferred stock will be distributed among and paid to those holders ratably in proportion to the amounts that would be payable to those holders if such assets were sufficient to permit payment in full. Any liquidation payment due upon a change of control transaction will be paid in the form of consideration paid in such change of control transaction on the closing date of the transaction.

“Accreted Value” means, as of any date, with respect to each share of Series A convertible preferred stock, the purchase price paid for such share, plus the amount of dividends that have accrued and compounded and have been added thereto to such date pursuant to the terms of the Certificate of the Powers, Designations, Preferences and Rights of the Series A Convertible Preferred Stock. “Compounding Date” means March 31, June 30, September 30 or December 31 of each year, each of which is a date upon which holders of shares of Series A convertible preferred stock are entitled to receive cumulative dividends quarterly in arrears.

Dividend Rights of Series A Convertible Preferred Stock

Shares of Series A convertible preferred stock pay a compounding dividend of 10% per annum, paid quarterly, in cash, or at the Company’s election, to be added to the liquidation preference of the Series A convertible preferred stock on a quarterly basis, which would result in an increase in the number of shares of common stock issuable upon conversion of the Series A convertible preferred stock. As of December 31, 2003, a total of $1.8 million in dividends has accrued on the outstanding Series A convertible preferred stock, which the Company elected to add to the liquidation preference of the Series A convertible preferred stock. Subject to changes in business conditions, the Company presently anticipates that the dividend will be added to the liquidation preference for the foreseeable future.

Conversion of Series A Convertible Preferred Stock

The holders of shares of Series A convertible preferred stock are entitled to convert their shares into common stock at any time. The number of shares of common stock issuable upon the conversion of a share of Series A convertible preferred stock is equal to the product of (x) the number of shares of Series A convertible preferred stock to be converted and (y) the quotient obtained by dividing the sum of the Accreted Value, plus all dividends accrued since the previous Compounding Date by the conversion price per share of the Series A convertible preferred stock, which conversion price initially was $1.12. The liquidation preference of the Series A convertible preferred stock was $1.19 per share as of December 31, 2003.

The applicable conversion price is subject to adjustment for stock splits, stock dividends, combinations, and other similar structural events. Additionally, the Series A convertible preferred stock provides for full-ratchet anti-dilution protection, subject to standard exceptions, with respect to the issuance of the Company’s capital stock at a purchase price per share which is below the conversion price of the Series A convertible preferred stock then in effect. If, on any date after May 15, 2005, the average market price for a share of common stock for the trailing 180 consecutive trading days is at least $7.50 (subject to adjustment for stock splits, stock dividends, combinations, and other similar structural events), then the Company may elect, at its option, to convert all, but not less than all, of the outstanding shares of Series A convertible preferred stock into the number of shares of common stock as is equal to the product of (x) the number of shares of Series A convertible preferred stock to be converted and (y) the quotient obtained by dividing the sum of (i) $1.12 and (ii) all accrued and unpaid dividends on such shares by the then applicable conversion price.

Voting Rights of Series A Convertible Preferred Stock

Holders of the Series A convertible preferred stock will have the right to vote on all matters that the holders of common stock vote on, voting together with the holders of common stock as single class. Each share of Series A convertible preferred stock will be entitled to the number of votes as is equal to the number of shares of the Company’s common stock into which it is convertible. However, the maximum number of votes to which a share of Series A convertible preferred stock will be entitled is capped at 0.7417, subject to adjustment to reflect stock splits, stock dividends, recapitalizations and the like.

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Preemptive Rights of Series A Convertible Preferred Stock

For so long as 5,350,000 of the shares of Series A convertible preferred stock remain outstanding, subject to adjustment to reflect stock splits, stock dividends, recapitalizations and the like, the purchasers will have preemptive rights for any private placement of equity securities by the Company.

7. STOCK BASED COMPENSATION

On October 24, 1994, the Board of Directors approved the Company’s 1994 Stock Option Plan (the “1994 Plan”), whose purpose is to encourage employees and other individuals who render services to the Company, by providing opportunities to purchase stock in the Company. The 1994 Plan authorizes the issuance of incentive stock options and nonqualified stock options. The 1994 Plan was terminated as to all new issuances of options effective as of the closing of the Company’s initial public offering. All options granted will expire ten years from their date of issuance. Incentive stock options granted generally have a four-year vesting period from their date of issuance and nonqualified options granted vest immediately upon their issuance.

In August 2000, the Board of Directors and stockholders approved the Company’s 2000 Stock Option and Incentive Plan (the “2000 Plan”), which became effective on the closing of the Company’s initial public offering. The purpose is to encourage employees and other individuals who render services to the Company, by providing opportunities to purchase stock in the Company. The 2000 Plan authorizes the issuance of incentive stock options and nonqualified stock options. All options granted will expire ten years from their date of issuance. Incentive stock options granted generally have a four-year vesting period from their date of issuance and nonqualified options granted vest immediately upon their issuance.

The following is a summary of stock option activity:

                 
            Weighted-
            Average
    Shares
  Exercise Price
Outstanding at January 1, 2001
    739,644     $ 4.66  
Granted
    400,100       5.14  
Exercised
    (19,391 )     0.95  
Terminated
    (5,041 )     3.23  
 
   
 
     
 
 
Outstanding at December 31, 2001
    1,115,312       4.94  
Granted
    60,000       1.86  
Exercised
    (11,429 )     0.84  
Terminated
    (17,505 )     3.34  
 
   
 
     
 
 
Outstanding at December 31, 2002
    1,146,378       4.84  
Granted
    4,137,447       1.75  
Exercised
    (5,500 )     1.21  
Terminated
    (14,388 )     3.65  
 
   
 
     
 
 
Outstanding at December 31, 2003
    5,263,937     $ 2.42  
 
   
 
     
 
 

Summarized information about stock options outstanding is as follows:

                                                         
                            Options Outstanding
  Options Exercisable
                            Weighted                
                            Average   Weighted           Weighted
Range of           Remaining   Average           Average
Exercise   Number   Contractual   Exercise   Number   Exercise
Prices
  Outstanding
  Life (Years)
  Price
  Exercisable
  Price
$0.22
    -     $ 1.54       774,348       9.16     $ 1.27       381,848     $ 1.01  
1.55
    -       1.60       45,000       10.34       1.58       35,000       1.59  
1.61
    -       1.61       2,000,000       12.38       1.61              
1.68
    -       1.95       61,000       10.60       1.71       12,000       1.85  
2.00
    -       2.00       1,518,000       12.34       2.00              
2.08
    -       5.00       530,093       7.56       3.00       322,407       3.01  
6.38
    -       11.04       186,477       6.99       8.44       128,731       8.26  
12.65
    -       12.65       6,000       7.42       12.65       6,000       12.65  
14.00
    -       14.00       127,019       6.84       14.00       95,262       14.00  
19.00
    -       19.00       16,000       6.84       19.00       13,500       19.00  
 
                   
 
     
 
     
 
     
 
     
 
 
December 31, 2003
    5,263,937       11.02     $ 2.42       994,748     $ 4.18  
 
                   
 
     
 
     
 
     
 
     
 
 

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At December 31, 2001, 2002 and 2003, options exercisable were 342,622, 614,394, and 994,748, respectively. Estimated weighted average fair value of options granted in fiscal years 2001, 2002 and 2003 were $5.14, $1.86 and $1.75, respectively, on the date of grant.

8. EMPLOYEE STOCK PURCHASE PLAN

In September 2000, the Company’s Board of Directors adopted a non-compensatory Employee Stock Purchase Plan (“the ESPP”). Under the ESPP, eligible employees of the Company who elect to participate are granted options to purchase common stock at a 15% discount from the market value of such stock. The ESPP permits an enrolled employee to make contributions to purchase shares of common stock by having withheld from their salary an amount between 0.1 percent and 10 percent of compensation, and a maximum of 25 shares per employee can be issued during each six-month payment period. The total number of shares of common stock that may be issued pursuant to options granted under the ESPP is 120,000. As of December 31, 2003, there were 3,100 shares issued under the ESPP.

9. WARRANTS

In connection with the Series A convertible preferred stock financing transaction (described in Note 6), Beacon Power Corporation purchased a warrant for $100,000, which is exercisable for 2,400,000 shares of the Company’s common stock at an exercise price of $3.37 per share. The warrant issued to Beacon Power Corporation is exercisable in whole (and not in part) at any time prior to May 14, 2006 and may not be exercised on a cashless basis. Additionally, Beacon Power Corporation purchased 892,857 shares of Series A convertible preferred stock for $1,000,000. The total proceeds of $1.1 million from Beacon Power Corporation were allocated between the Series A convertible preferred stock ($475,000) and the warrant ($625,000) based on their relative fair values. The fair value of the warrant was calculated using the Black-Scholes pricing model with the following assumptions: dividend yield of zero percent; expected volatility of 90%; risk free interest rate of 2% and a term of three years. The difference between the proceeds allocated to the relative fair value of the warrant, $625,000, and the amount paid for the warrant, $100,000, or $525,000 contributed to the accretion charge of $11.7 million for the year ended December 31, 2003.

10. EMPLOYEES’ SAVINGS PLAN

The Company established a 401(k) plan in 1996 for eligible employees. Under the provisions of the plan, eligible employees may voluntarily contribute a portion of their compensation up to the statutory limit. In addition, the Company can make a matching contribution at its discretion. As of December 31, 2003, the Company has not made any contributions to the plan.

11. COMMITMENTS

LEASE

On March 13, 2000, the Company entered into a ten-year lease commencing July 1, 2000, for office and manufacturing space in Marlboro, Massachusetts. Pursuant to the terms of the lease agreement, the Company will pay annual rent ranging from $464,000 in the first year to $534,000 during the last year of the lease. Rent is payable on the first day of each month and is collateralized by a $414,000 standby letter of credit. In connection with this arrangement, the Company invested in a certificate of deposit pledged to a commercial bank. This certificate of deposit was classified as “restricted cash” on the December 31, 2002 and 2003 balance sheet. The following is a schedule, by year, of future minimum rental payments required under the ten-year lease that have remaining noncancelable lease terms in excess of one year as of December 31, 2003:

         
2004
  $ 492,188  
2005
    499,219  
2006
    506,250  
2007
    513,281  
2008
    527,344  
Thereafter
    801,563  
 
   
 
 
Total
  $ 3,339,845  
 
   
 
 

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Occupancy expense, which includes rent, property taxes, and other operating expenses associated with our Marlboro manufacturing facility, was $795,000, $674,000, and $680,000 for the years ended December 31, 2001, 2002, and 2003, respectively.

LICENSE AGREEMENT

In September 1994, the Company signed an agreement to license String Ribbon technology from a professor at Massachusetts Institute of Technology. Concurrently, the Company hired the professor as a consultant. This agreement provides the Company, its successors, assigns, and legal representatives an irrevocable, worldwide right and license in and to the technology and licensed patents, including the right to make, have made, use, lease, sub-license, and sell products and to enforce any of the patent rights of the licensed patents. The license is exclusive except for rights to the licensed patents held by the U.S. Department of Energy. In exchange for these rights, the consultant will earn royalties on sales of products through 2004. The Company incurred $25,000, $25,000 and $54,767 in royalty expense for the years ended December 31, 2001, 2002 and 2003, respectively. The Company can, at any time, cease utilization of the technology with no further royalty payments.

12. SEGMENT INFORMATION

The Company operates as one segment. The following table summarizes the Company’s concentration of total revenue:

                 
% of Total revenue
  2002
  2003
By geography:
               
U.S. distributors
    25 %     29 %
U.S. Government (research revenue)
    21 %     24 %
Germany
    44 %     36 %
Japan
    2 %     4 %
All other
    8 %     7 %
 
   
 
     
 
 
 
    100 %     100 %
By customer:
               
European distributor
    44 %     39 %
National Institute of Industry Standards (research revenue)
    11 %     7 %
National Renewable Energy Laboratory (research revenue)
    10 %     10 %
All other
    35 %     44 %
 
   
 
     
 
 
 
    100 %     100 %

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13. UNAUDITED QUARTERLY RESULTS

The following tables set forth unaudited selected financial information for the periods indicated. This information has been derived from unaudited consolidated condensed financial statements, which, in the opinion of management, include all adjustments (consisting only of normal recurring adjustments) necessary for a fair presentation of such information. The Company’s independent auditors have not audited this information. The results of operations for any quarter are not necessarily indicative of the results to be expected for any future period.

QUARTERLY STATEMENT OF OPERATIONS
(IN THOUSANDS, EXCEPT PER SHARE DATA)
UNAUDITED

                                                                 
    MAR 31,   JUN 30,   SEP 30,   DEC 31,   MAR 31,   JUN 30,   SEP 30,   DEC 31,
    2002
  2002
  2002
  2002
  2003
  2003
  2003
  2003
Revenues:
                                                               
Product revenues
  $ 913     $ 1,075     $ 1,461     $ 1,847     $ 1,067     $ 2,659     $ 2,642     $ 1,378  
Research revenues
    236       207       641       364       381       508       463       213  
 
   
 
     
 
     
 
     
 
     
 
     
 
     
 
     
 
 
Total revenues
    1,149       1,282       2,102       2,211       1,448       3,167       3,105       1,591  
Operating expenses:
                                                               
Cost of product revenues
    2,904       2,791       3,041       3,669       2,666       4,242       4,061       4,410  
Research and development expenses
    854       989       935       915       713       1,072       1,087       919  
Selling, general and administrative expenses
    1,054       1,187       991       1,287       1,317       1,202       1,301       1,517  
 
   
 
     
 
     
 
     
 
     
 
     
 
     
 
     
 
 
Total operating expenses
    4,812       4,967       4,967       5,871       4,696       6,516       6,449       6,846  
Operating loss
    (3,663 )     (3,685 )     (2,865 )     (3,660 )     (3,248 )     (3,349 )     (3,344 )     (5,255 )
Interest income
    242       210       133       89       23       50       83       66  
 
   
 
     
 
     
 
     
 
     
 
     
 
     
 
     
 
 
Net loss
    (3,421 )     (3,475 )     (2,732 )     (3,571 )     (3,225 )     (3,299 )     (3,261 )     (5,189 )
Accretion of Series A convertible preferred stock
                                  (12,055 )     (747 )     (696 )
 
   
 
     
 
     
 
     
 
     
 
     
 
     
 
     
 
 
Net loss attributable to common stockholders
    (3,421 )     (3,475 )     (2,732 )     (3,571 )     (3,225 )     (15,354 )     (4,008 )     (5,885 )
Other comprehensive income (loss):
                                                               
Unrealized gain (loss) on investments
    155       (62 )     (46 )     (40 )     (6 )     (55 )     22       5  
 
   
 
     
 
     
 
     
 
     
 
     
 
     
 
     
 
 
Comprehensive loss attributable to common stockholders
  $ (3,266 )   $ (3,537 )   $ (2,778 )   $ (3,611 )   $ (3,231 )   $ (15,409 )   $ (3,986 )   $ (5,880 )
 
   
 
     
 
     
 
     
 
     
 
     
 
     
 
     
 
 
Net loss per common share (basic and diluted)
  $ (0.30 )   $ (0.30 )   $ (0.24 )   $ (0.31 )   $ (0.28 )   $ (1.35 )   $ (0.35 )   $ (0.43 )
Weighted average shares used in computing basic and diluted net loss per common share
    11,398       11,404       11,408       11,410       11,411       11,412       11,497       13,600  

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14. VALUATION AND QUALIFYING ACCOUNTS

The following table sets forth activity in the Company’s valuation and qualifying accounts:

                                 
    Balance at                
    beginning   Charged to           Balance at
Description
  of period
  operations
  Deductions
  end of period
Year ended December 31, 2001
                               
Reserves and allowances deducted from assets accounts:
                               
Valuation allowance for deferred tax assets
  $ 7,047,000     $ 5,005,000     $     $ 12,052,000  
Allowance for doubtful accounts
    13,000                   13,000  
Accrued warranty
    48,000       90,000             138,000  
Year ended December 31, 2002
                               
Reserves and allowances deducted from assets accounts:
                               
Valuation allowance for deferred tax assets
  $ 12,052,000     $ 5,099,000     $     $ 17,151,000  
Allowance for doubtful accounts
    13,000       127,000             140,000  
Accrued warranty
    138,000       188,000             326,000  
Year ended December 31, 2003
                               
Reserves and allowances deducted from assets accounts:
                               
Valuation allowance for deferred tax assets
  $ 17,151,000     $ 5,757,000     $     $ 22,908,000  
Allowance for doubtful accounts
    140,000       87,000             227,000  
Accrued warranty
    326,000       100,000             426,000  

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SIGNATURES

Pursuant to the requirements of Section 13 or 15(d) of the Securities Exchange Act of 1934, the registrant has duly caused this report to be signed on its behalf by the undersigned on this 23d day of March, 2004, thereunto duly authorized.

         
  EVERGREEN SOLAR, INC.
 
       
  By:   /s/ Richard M. Feldt
      Richard M. Feldt
      Chief Executive Officer,
      President and Director

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POWER OF ATTORNEY AND SIGNATURES

We, the undersigned officers and directors of Evergreen Solar, Inc., hereby severally constitute and appoint Richard M. Feldt and Richard G. Chleboski, and each of them singly, our true and lawful attorneys, with full power to both of them and each of them singly, to sign for us and in our names in the capacities indicated below, any amendments to this Annual Report on Form 10-K, and generally to do all things in our names and on our behalf in such capacities to enable Evergreen Solar, Inc. to comply with the provisions of the Securities Exchange Act of 1934, as amended, and all the requirements of the Securities and Exchange Commission.

     Pursuant to the requirements of the Securities Exchange Act of 1934, this report has been signed below by the following persons on behalf of the registrant and in the capacities and on the dates indicated.

         
Name
  Title
  Date
/s/ Richard M. Feldt
Richard M. Feldt
  Chief Executive Officer,
President and Director
(Principal Executive Officer)
  March 23, 2004
 
       
/s/ Mark A. Farber
Mark A. Farber
  Vice President,
Director
  March 23, 2004
 
       
/s/ Brown F. Williams
Brown F. Williams
  Chairman of the Board of Directors   March 23, 2004
 
       
/s/ Luc Charron
Luc Charron
  Director   March 23, 2004
 
       
/s/ Philip J. Deutch
Philip J. Deutch
  Director   March 23, 2004
 
       
/s/ Charles J. McDermott
Charles J. McDermott
  Director   March 23, 2004
 
       
/s/ Robert W. Shaw, Jr.
Robert W. Shaw, Jr.
  Director   March 23, 2004
 
       
/s/ William P. Sommers
William P. Sommers
  Director   March 23, 2004
 
       
/s/ Timothy Woodward
Timothy Woodward
  Director   March 23, 2004

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