Battery Cell Design &
Chemistry Consulting
We help you select and validate the optimal cell chemistry (LFP, NMC, NCA,
etc.) and design for your application's specific requirements, balancing energy density, power, cost, and
lifespan. Our experts guide you through the complex trade-offs to build a foundational competitive
advantage.
- Match battery performance precisely to product requirements.
- Reduce supply chain risk by selecting viable, scalable chemistries.
- Lay the groundwork for superior battery pack performance and safety.
Battery Management System (BMS)
Development
Our team designs and develops robust, custom BMS hardware and firmware to
ensure the safety, reliability, and longevity of your battery pack. We implement critical functions like
cell balancing, SoC/SoH estimation, and fault detection for automotive, industrial, and consumer
applications.
- Maximize usable battery capacity and extend operational life.
- Ensure operational safety by preventing over-charge, over-discharge, and thermal events.
- Develop custom features for your specific application needs.
Thermal Management &
Simulation (CFD)
Using advanced Computational Fluid Dynamics (CFD) tools like Ansys Fluent,
we model, simulate, and optimize thermal management systems (air, liquid, or phase-change). We ensure your
battery operates within its ideal temperature range, preventing degradation and thermal runaway.
- Increase battery lifespan by up to 25% through optimized cooling.
- Enable higher charge/discharge rates safely.
- Reduce physical prototyping costs by validating designs virtually.
Battery Pack Design &
Mechanical Engineering
We provide end-to-end mechanical design for battery packs using tools like
CATIA and SolidWorks. This includes structural enclosure design, busbar engineering, vibration and shock
analysis (FEA), and design for manufacturability (DFM) to create a durable, cost-effective, and
serviceable pack.
- Ensure structural integrity and resilience in harsh environments.
- Optimize for weight, space, and ease of assembly.
- Design for compliance with standards like IEC 62133 and UN 38.3.
High-Voltage System Architecture
For EV and grid-scale applications, we design safe and efficient
high-voltage (400V/800V+) architectures. This includes component selection (contactors, fuses), insulation
coordination, and developing strategies for managing creepage and clearance to ensure operator and system
safety.
- Ensure compliance with high-voltage safety standards (e.g., LV 123).
- Minimize power losses and maximize system efficiency.
- Design robust systems for reliable, long-term operation.
AI-Based SoC/SoH Estimation
Modeling
Go beyond traditional coulomb counting. We develop and train advanced AI/ML
models (e.g., using recurrent neural networks) to provide highly accurate State of Charge (SoC) and State
of Health (SoH) estimations, even with aging batteries and varying operational conditions.
- Provide users with a highly accurate and reliable 'gas gauge'.
- Enable predictive maintenance and accurate end-of-life forecasting.
- Improve battery performance by optimizing control strategies based on true health.
Firmware & Embedded Systems
for Batteries
Our embedded software experts write clean, reliable, and real-time firmware
for your BMS microcontrollers. We focus on efficient algorithm implementation, robust fault handling, and
secure communication protocols (like CAN bus) to create the intelligent core of your battery system.
- Ensure real-time performance for critical safety functions.
- Develop modular, maintainable code for future updates.
- Implement secure bootloaders and over-the-air (OTA) update capabilities.
Functional Safety Analysis (ISO
26262)
For automotive applications, achieving functional safety is non-negotiable.
Our TUV-certified experts guide you through the entire ISO 26262 lifecycle, from Hazard Analysis and Risk
Assessment (HARA) to developing safety goals and implementing ASIL-rated hardware and software.
- De-risk your product launch by building safety in from the start.
- Create the required documentation and work products for certification.
- Design fail-operational systems that protect users and prevent recalls.
Battery Testing & Validation
Protocol Design
A design is only as good as its validation. We create comprehensive Design
Verification Plan and Report (DVP&R) protocols to test every aspect of your battery's performance,
safety, and reliability against industry standards and your specific requirements.
- Confidently validate that your battery meets all specifications.
- Identify design weaknesses early in the development cycle.
- Generate the necessary data for certification and homologation.
Homologation & Certification
Support
Navigating the complex web of global battery regulations is a major
challenge. We provide expert support to prepare your product and documentation for certification standards
like UN 38.3, IEC 62133, UL standards, and CE marking, ensuring a smoother path to market access.
- Avoid costly delays caused by failed certification attempts.
- Understand and meet requirements for your target markets.
- Streamline the creation of technical files and compliance documentation.
Digital Twin & Predictive
Maintenance
We build high-fidelity digital twins of your battery systems. These virtual
models, fed by real-world data, allow for advanced predictive maintenance, what-if scenario analysis, and
optimization of operational strategies, maximizing the asset's value over its entire lifecycle.
- Predict and prevent failures before they occur, increasing uptime.
- Optimize charging strategies in real-time to extend battery life.
- Accurately model degradation to plan for second-life applications.
Value Engineering & Cost
Optimization
We systematically analyze your battery design's bill of materials (BOM) and
manufacturing process to identify opportunities for cost reduction without sacrificing performance or
reliability. This can include material substitution, component consolidation, or design-for-assembly
improvements.
- Reduce per-unit production costs and increase profit margins.
- Maintain a competitive price point in the market.
- Achieve cost targets for high-volume manufacturing.
Manufacturing Process & DFM
Support
We bridge the gap between design and production. Our engineers provide
Design for Manufacturability (DFM) and Design for Assembly (DFA) feedback to ensure your battery pack can
be built reliably, at scale, and within cost targets, collaborating with your manufacturing partners.
- Reduce assembly time and labor costs.
- Minimize manufacturing defects and improve yield.
- Ensure a smooth transition from prototype to mass production.
End-of-Life (EoL) &
Second-Life Strategy
We help you plan for the entire battery lifecycle, including sustainable
end-of-life and profitable second-life applications (e.g., for residential energy storage). This
forward-thinking approach addresses regulatory requirements and opens up new revenue streams.
- Comply with emerging circular economy and recycling regulations.
- Create new business models from retired battery assets.
- Enhance your brand's sustainability credentials.
Prototyping & Supplier
Sourcing
Leveraging our global network, we assist in sourcing components and managing
the fabrication of prototype battery packs. We help you get functional hardware for testing and validation
quickly, accelerating the feedback loop between design and physical reality.
- Accelerate the prototyping phase of your project.
- Access a wider range of component suppliers.
- Get hands-on with your design faster to validate key assumptions.
