Battery Design

Engineering batteries for what comes next.

From battery architecture to application-specific systems, we develop solutions around how energy needs to perform.

The application

A battery starts with what it needs to do.

Every application places different demands on its energy system. Battery design begins by understanding those requirements before defining the system around them.

  • 01Energy
  • 02Power
  • 03Form
A ReBAT battery pack with a green lid, terminal posts and a grey connector lead
Application
  • 04Environment
  • 05Integration
  • 06Intended use
From requirement to architecture

Turning application requirements into a battery system.

The design process begins with understanding the application and progressively translating its requirements into a battery architecture.

High-level stages of the design approach, scoped to each application.

  1. 01

    Understand

    Application, operating conditions and energy requirements.

  2. 02

    Define

    Translate the application requirements into battery-level requirements.

  3. 03

    Architect

    Develop the battery configuration around those requirements.

  4. 04

    Engineer

    Develop the physical system around the intended application.

  5. 05

    Evaluate

    Assess the solution against the requirements it was designed around.

  6. 06

    Refine

    Iterate toward an application-ready solution.

Battery architecture

From cells to a complete system.

A battery is more than its individual cells. Its architecture determines how those components come together to serve the application.

  1. Two cylindrical battery cells01

    Cell

    The basic unit that stores energy.

  2. Cylindrical cells grouped and wired into a module02

    Module

    Cells grouped and connected together.

  3. A complete ReBAT battery pack with enclosure and connectors03

    Pack

    Modules brought together as a complete battery.

  4. Racked battery energy storage hardware in an industrial hall04

    Application

    Where the battery does its work.

Designed around the real world

Designed around the way energy is used.

The right battery configuration depends on the environment, operating requirements and system it is designed to support.

01Energy
How much energy does the application require?
02Power
How does that energy need to be delivered?
03Form
Where does the battery need to fit?
04Environment
What conditions does it need to operate in?
05Integration
How does it become part of the larger system?
06Application
What is the battery ultimately being built to do?
Application-specific

One battery does not fit every application.

Battery architecture changes with the environment, operating requirements and system it is designed to support.

  1. 01

    Solar Street Light

    Every night, every season, no site visits.

    • 12.8V 30Ah · 0.38 kWh
  2. 02

    EV 2W Low Speed

    A 60V pack for low-speed electric two-wheelers.

    • 60V 30Ah · 1.80 kWh
See the full range
Engineered system

Where energy becomes an engineered system.

A battery pack opened to show its cell stack, copper busbars and wiring on a workshop floor
Annotations describe what is visible in the photograph. They are not a specification.
  1. 01

    Enclosure

    The housing that holds the pack together.

  2. 02

    Cell stack and busbars

    Cells arranged and joined by copper conductors.

  3. 03

    Wiring and connections

    How the pack is connected onward.

BMS and communications

Every BMS protection and every pack is verified before dispatch.

Engineering + validation

Designed to meet the application.

Engineering is only useful when the resulting system meets the requirements it was designed around.

  1. 01
    Requirement
  2. 02
    Design
  3. 03
    Evaluation
  4. 04
    Refinement
  5. 05
    Solution

Evaluation feeds back into design until the solution meets the requirement.

Testing and quality control

Every cell tested. Every pack proven.

A battery is only as good as its weakest cell. That's why we test every cell before it enters production, check quality at every stage of assembly, age every pack, and run a final end-of-line test on the BMS and battery before it leaves our factory. Nothing ships on trust, only on test results.

  1. 01

    Cell IQC

    Every incoming cell is tested before it enters production.

    • Open circuit voltage (OCV)
    • Internal resistance (IR)
    • Capacity
    • Self-discharge
  2. 02

    In-process QC

    Quality checks at every stage of assembly, not just at the end.

    • Cell grading and matching
    • Check at each build stage
    • Stage sign-off before moving on
  3. 03

    Aging test

    Packs are held and cycled to catch early failures before dispatch.

    • Charge-discharge cycling
    • Voltage stability check
    • Weak packs rejected
  4. 04

    EOL test

    Final end-of-line test on BMS and battery before it ships.

    • BMS protection and function
    • Communication (CAN/UART)
    • Full pack performance
A blue testing cabinet with shelves of cylindrical cells on charge and discharge trays
Cell testing cabinet
Close view of cells seated on a cabinet tray with indicator lights
Channel by channel
A testing cabinet with every shelf loaded with cells
Cells under test

What each test means for you

OCV and IR check
Only healthy, matched cells go into a pack, so every cell works evenly and the pack lasts longer.
Capacity test
The Ah on the label is the Ah you get.
Self-discharge test
Weak cells are removed, so the battery holds charge in storage and on the pole.
Aging test
Early failures happen in our factory, not in your field, vehicle or home.
EOL test
Every BMS protection and every pack is verified before dispatch.
  • 100% cell testing (OCV, IR, Capacity, Self-discharge)
  • QC at every stage
  • Aging tested
  • EOL tested
Part of a larger lifecycle

Designed within a larger battery ecosystem.

The battery lifecycle does not end when a battery is designed or deployed. What is designed today can shape what happens to the battery tomorrow.

  1. Battery design (this page)Solution
  2. UseProducts: Battery packs
  3. Collection
  4. Reverse logisticsSolution
  5. Recovery
  6. MaterialsProducts: Recovered materials
  7. R&DSolution
  8. Next application
Responsibility runs the length of the lifecycle: EPR
Spent batteries in a collection bin feeding a conveyor
Collection
Bags of black mass being fed into a processing line
Recovery
Copper, graphite and metal powders on a concrete surface
Materials

Have an application in mind?

Tell us what you need to power. We'll explore the right battery solution with you.