Battery Engineering Outsourcing Services
Accelerate your product roadmap and de-risk development. Access an elite, managed team of battery engineers on-demand.
From EV startups to consumer electronics giants, the race to develop safer, more powerful, and longer-lasting batteries is relentless. The biggest bottleneck? Access to specialized engineering talent. We provide a dedicated, CMMI Level 5 certified team to handle every stage of your battery development lifecycle, helping you innovate faster and more cost-effectively than your competition.
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Why Outsource Battery Engineering?
The global transition to electrification is creating unprecedented demand for battery expertise. Yet, finding, hiring, and retaining top-tier battery engineers is a major challenge for companies of all sizes. Outsourcing provides a strategic advantage, allowing you to tap into a global talent pool, reduce fixed overhead costs, and accelerate your development cycles to seize market opportunities faster.
The LiveHelpIndia Advantage
Ironclad IP Security
Your intellectual property is your most valuable asset. We protect it with ISO 27001 & SOC 2 certified processes, strict NDAs, and full IP rights transfer, giving you enterprise-grade security and peace of mind.
Accelerated Time-to-Market
Bypass lengthy recruitment cycles. We deploy expert engineers in as little as 48-72 hours, integrating them seamlessly into your workflow to get your project moving immediately and hit critical market windows.
Significant Cost Reduction
Reduce your burn rate by up to 60%. Avoid the high costs of local salaries, benefits, and infrastructure. Our managed outsourcing model provides access to top talent at a fraction of the cost of an in-house team.
Deep Domain Expertise
Gain access to specialists across the entire battery ecosystem, from cell chemistry and pack design to BMS firmware and thermal simulation. We match you with the precise skills you need for your specific application.
Agile & Scalable Teams
Your project needs can change. We provide the flexibility to scale your team up or down on demand, ensuring you always have the right resources at the right time without being locked into long-term commitments.
End-to-End Managed Service
We're not a body shop. We provide a fully managed service that includes project oversight, QA, and dedicated support. You can focus on your core product vision while we handle the engineering execution.
Advanced Tool Proficiency
Our engineers are proficient in industry-standard tools like MATLAB/Simulink, Altium, CATIA, Ansys, and COMSOL, ensuring they can integrate with your existing toolchain and deliver high-quality, reliable results.
Proven CMMI Level 5 Process
Our CMMI Level 5 appraisal signifies the highest level of process maturity. This commitment to quality minimizes errors, ensures predictable outcomes, and delivers consistent, high-quality engineering work.
Risk-Free Engagement
Start with a 2-week paid trial to ensure a perfect fit. Our free-replacement guarantee means if you're ever unsatisfied with performance, we'll swap in a new expert with zero knowledge transfer cost to you.
Our Comprehensive Battery Engineering Services
We offer an end-to-end suite of services covering the entire battery development lifecycle. Whether you need support for a specific stage or a full turnkey solution, our expert team is equipped to deliver.
Custom Battery Pack Design & Development
We design and develop high-performance, reliable, and manufacturable battery packs tailored to your specific application, whether it's for an EV, a consumer device, or a grid storage system.
- Mechanical design including housing, cell interconnects, and structural components.
- Electrical design including wiring, fusing, and safety circuit integration.
- Selection and sourcing of optimal cells based on performance, cost, and availability.
Battery Management System (BMS) Development
The BMS is the brain of your battery. We develop custom hardware and firmware to ensure optimal performance, safety, and longevity of your battery pack.
- Hardware design, component selection, and PCB layout.
- Firmware development for state-of-charge (SOC), state-of-health (SOH), and cell balancing algorithms.
- Implementation of safety protocols for over-voltage, under-voltage, and over-temperature protection.
Cell Selection and Characterization
Choosing the right cell is the foundation of a successful battery pack. We provide data-driven analysis to select the best cell technology for your requirements.
- Comprehensive market analysis of available cell technologies (LFP, NMC, etc.).
- In-depth testing and characterization to validate manufacturer datasheets.
- Lifecycle and performance modeling to predict long-term behavior.
DFM/DFA for Battery Systems
We embed Design for Manufacturability (DFM) and Design for Assembly (DFA) principles from day one to ensure your battery pack is not only high-performing but also cost-effective to produce at scale.
- Collaboration with manufacturing partners to align design with production capabilities.
- Cost optimization through material selection and process simplification.
- Creation of detailed manufacturing process instructions and quality control plans.
Prototyping and Pilot Production Support
We bridge the gap between design and mass production by managing the prototyping and pilot run phases, ensuring a smooth transition to manufacturing.
- Rapid prototyping for design validation and functional testing.
- Supplier qualification and management for pilot production.
- Development of assembly jigs, fixtures, and end-of-line testing equipment.
Thermal Management & Simulation
Effective thermal management is critical for battery safety and lifespan. We use advanced simulation tools to design and validate cooling and heating systems.
- CFD analysis to model heat generation and dissipation within the pack.
- Design of air, liquid, or phase-change material cooling systems.
- Simulation of performance under extreme environmental conditions.
Structural & Vibration Analysis (FEA)
We ensure your battery pack can withstand the mechanical stresses of its intended environment, particularly for automotive and aerospace applications.
- Finite Element Analysis (FEA) to simulate shock, vibration, and impact events.
- Optimization of pack structure for weight reduction while maintaining durability.
- Compliance analysis for industry standards like UN 38.3 and IEC 62133.
Battery Performance Modeling
We create accurate electrochemical and equivalent circuit models to predict battery performance, aging, and behavior under various load profiles.
- Development of high-fidelity models in MATLAB/Simulink or similar platforms.
- Simulation of driving cycles, power profiles, and fast-charging scenarios.
- Aging prediction models to estimate battery lifespan and degradation.
Safety & Abuse Simulation
We proactively identify and mitigate potential safety hazards by simulating abuse conditions like short circuits, thermal runaway, and crush events.
- Modeling of thermal runaway propagation and containment strategies.
- Short circuit and overcharge simulation to validate safety circuit effectiveness.
- Analysis of cell venting and gas management systems.
System-Level Integration Modeling
We model the interaction between the battery pack and the larger system (e.g., EV powertrain, power grid) to optimize overall performance and efficiency.
- Co-simulation of battery, motor, and controller for electric vehicles.
- Analysis of battery impact on power grid stability for energy storage systems.
- Development of control strategies to optimize energy usage and system efficiency.
Test Plan Development & Automation
We create comprehensive Design Verification Plan and Report (DVP&R) documents and develop automated testing scripts to ensure thorough and efficient validation.
- Definition of test cases covering performance, safety, and reliability.
- Development of automated test scripts using Python, LabVIEW, or other platforms.
- Integration with battery cyclers, environmental chambers, and data acquisition systems.
Functional & Performance Testing
We rigorously test battery packs and BMS units to verify they meet all functional and performance specifications defined in the design phase.
- Capacity, impedance, and power capability testing.
- BMS functional validation, including SOC/SOH accuracy and fault detection.
- Efficiency testing under various charge/discharge cycles.
Safety & Abuse Testing Coordination
We manage and oversee the execution of critical safety and abuse tests at certified third-party labs to ensure regulatory compliance.
- Coordination of tests like nail penetration, crush, short circuit, and overcharge.
- Ensuring compliance with standards such as UN 38.3, IEC 62133, and UL standards.
- Detailed failure analysis and reporting in case of test failures.
Environmental & Reliability Testing
We subject battery packs to a range of environmental conditions to validate their durability and reliability over their intended service life.
- Thermal cycling and shock testing in environmental chambers.
- Vibration and mechanical shock testing on shaker tables.
- Ingress Protection (IP) testing for water and dust resistance.
Homologation & Certification Support
Navigating the complex landscape of global regulations is challenging. We provide expert support to help you achieve the necessary certifications for your target markets.
- Compilation of all necessary technical documentation for certification bodies.
- Guidance on regional standards (e.g., CE, FCC, R100).
- Liaison with test labs and regulatory agencies on your behalf.
Our Proven Development Process
1. Discovery & Requirements
We start with a deep dive into your project goals, technical specifications, and business objectives to ensure complete alignment from day one.
2. Team Assembly & Onboarding
We handpick a dedicated team of engineers with the precise skills for your project and onboard them into your workflow within 48-72 hours.
3. Agile Design & Development
Working in agile sprints, we proceed with design, simulation, and prototyping, providing regular updates and incorporating your feedback at every stage.
4. Rigorous Validation & Testing
We execute a comprehensive test plan to validate every aspect of the design, from performance and reliability to safety and compliance.
5. Manufacturing Handoff & Support
We provide a complete documentation package and offer ongoing support to your manufacturing partners to ensure a smooth transition to mass production.
Technology Stack & Tools We Master
Our teams are experts in the industry-standard software and platforms essential for modern battery engineering.
Success Stories: Real-World Impact
Accelerating BMS Development for an EV Startup
Industry: Electric Vehicles
Client Overview: A well-funded EV startup in California was developing a revolutionary electric motorcycle. Their in-house team was stretched thin, and their critical path was blocked by the complex task of developing a custom, automotive-grade Battery Management System (BMS) from scratch. They needed to accelerate their timeline to meet investor milestones and secure their next funding round.
"LiveHelpIndia didn't just give us engineers; they gave us a strategic advantage. Their BMS team integrated flawlessly and delivered a production-ready system months ahead of our internal schedule. We wouldn't have hit our launch date without them."
- Alex Royce, CTO, EV Innovate Inc.
Key Challenges:
- Aggressive development timeline to meet investor deadlines.
- Requirement for high-accuracy SOC/SOH algorithms.
- Need for compliance with automotive safety standards (ISO 26262).
- Limited in-house expertise in BMS firmware development.
Our Solution:
- Deployed a dedicated team of 4 engineers (2 firmware, 1 hardware, 1 validation).
- Developed custom cell balancing and state estimation algorithms in Embedded C.
- Implemented a robust safety architecture compliant with ISO 26262 ASIL-C.
- Created an automated HIL (Hardware-in-the-Loop) testing environment for rapid validation.
Optimizing Battery Life for a Next-Gen Wearable
Industry: Consumer Electronics
Client Overview: A leading European consumer electronics brand was designing a new flagship smartwatch. A key selling point was "all-week battery life," but their initial prototypes were falling short. They needed specialized expertise in low-power design and battery performance optimization without derailing their product launch schedule.
"The battery performance analysis from the LiveHelpIndia team was a game-changer. Their insights allowed us to make critical design changes that pushed our device's battery life beyond the marketing goal. Their expertise was invaluable."
- Eva Warren, Head of R&D, TechWearables GmbH
Key Challenges:
- Severe space constraints for the battery within the device casing.
- High power consumption from a new, high-resolution display.
- Need to accurately model battery drain across various user scenarios.
- Short timeline to find a solution before design freeze.
Our Solution:
- Provided a senior battery engineer to perform in-depth power profile analysis.
- Created a high-fidelity battery model to simulate performance and identify optimization opportunities.
- Recommended a higher energy-density Li-Po cell and optimized the charging algorithm.
- Collaborated with the client's firmware team to implement power-saving software modes.
Designing a Megawatt-Scale Grid Energy Storage System
Industry: Renewable Energy
Client Overview: An Australian renewable energy company won a contract to build a 5 MWh Battery Energy Storage System (BESS) for grid stabilization. While experienced in solar farm deployment, they lacked the in-house expertise to design the complex battery pack, thermal management, and safety systems required for a utility-scale project.
"For our first BESS project, we needed a partner we could trust. LiveHelpIndia delivered a robust, compliant, and cost-effective system design. Their thermal simulation work was particularly impressive, giving us the confidence to deploy in the harsh Australian climate."
- Henry Coleman, Chief Engineer, GridScale Energy
Key Challenges:
- Designing for high ambient temperatures and extreme thermal cycling.
- Ensuring system safety and mitigating thermal runaway risk at a large scale.
- Meeting stringent grid connection standards and regulations.
- Optimizing the system for cost-per-kWh while ensuring a 15-year lifespan.
Our Solution:
- Designed a modular battery rack system using LFP cells for enhanced safety and longevity.
- Performed extensive CFD thermal simulations to design an efficient liquid cooling system.
- Developed a multi-layered safety system, including pack-level fusing and fire suppression.
- Provided a complete design package for manufacturing, including all schematics, BOM, and assembly instructions.
Meet Your Battery Engineering Experts
Our team isn't just a collection of engineers; they are industry veterans and specialists passionate about energy storage technology. When you partner with us, you get access to this deep well of experience.
Akeel Q.
Manager, Certified AI & Machine Learning Specialist, Cloud Solutions Expert
Prachi D.
Manager, Certified Cloud & IoT Solutions Expert, AI Solutions Expert
Ravindra T.
Manager, Certified Cloud & IoT Solutions Expert
Girish S.
Delivery Manager, Microsoft Certified Solutions Architect
Flexible Engagement Models
We understand that every project is unique. That's why we offer flexible engagement models designed to fit your specific needs, budget, and timeline.
Dedicated Team Model
An entire team of engineers is allocated exclusively to your project, acting as a seamless extension of your in-house team. This model is ideal for long-term projects requiring deep integration and a wide range of skills.
Staff Augmentation
Augment your existing team with one or more of our expert engineers to fill specific skill gaps or to add bandwidth for a critical project phase. You manage the resources directly, giving you maximum control.
Project-Based Model
Define the project scope, and we'll deliver it for a fixed price. This model is perfect for well-defined projects with clear deliverables, providing you with cost certainty and minimizing your management overhead.
What Our Clients Say
"The outsourced battery simulation team was exceptional. Their thermal analysis was more detailed than what we could produce in-house and directly led to a safer, more reliable product. The ROI was immediate."
"As a startup, speed is everything. LiveHelpIndia provided two senior BMS firmware engineers in three days, allowing us to hit a critical software milestone. Their flexibility and the quality of their talent are unmatched."
"We needed to validate a new battery pack design against UN 38.3 standards. LiveHelpIndia's team managed the entire process, from test plan development to coordinating with the lab. It saved our team hundreds of hours."
"IP security was our biggest concern with outsourcing. LiveHelpIndia's ISO 27001 certification and transparent processes gave our legal team the confidence to move forward. They treat our data with the highest level of care."
"The cost savings are significant, but the real value is the expertise. We have access to a level of battery engineering talent that would be impossible for us to recruit and retain locally. It's a true competitive advantage."
"Their DFM analysis on our battery pack design saved us over 15% in manufacturing costs before we even built the first prototype. Their proactive approach and manufacturing knowledge are top-notch."
Ready to Power Your Innovation?
Stop letting talent shortages slow you down. Let's discuss how our managed battery engineering services can help you accelerate your roadmap, reduce costs, and out-innovate your competition. Schedule a free, no-obligation consultation with our solutions expert today.
Schedule Your Free ConsultationFrequently Asked Questions
We take IP protection extremely seriously. Our entire engagement is governed by a robust Non-Disclosure Agreement (NDA). All IP developed during the project is transferred to you upon completion of payments. Furthermore, our operations are ISO 27001 and SOC 2 certified, which means we adhere to strict international standards for information security management, including access controls, data encryption, and secure development environments.
Yes. Our talent pool includes engineers with diverse specializations across a wide range of battery chemistries, including various Lithium-Ion formulations (NMC, LFP, NCA, LCO), Lithium-Polymer, and we are actively engaged in projects involving emerging technologies like solid-state batteries. During the discovery phase, we ensure we match your project with engineers who have direct, hands-on experience with your required chemistry and application.
Seamless collaboration is key to our model. We establish a significant timezone overlap (typically 4-6 hours) for real-time meetings and discussions. Our teams are proficient in agile methodologies and use standard collaboration tools like Jira, Slack, Confluence, and Microsoft Teams. A dedicated project manager acts as your single point of contact, ensuring clear, consistent communication and perfect alignment with your project goals and internal processes.
Our streamlined recruitment and onboarding process is designed for speed. After finalizing the requirements, we can typically present you with profiles of qualified, pre-vetted engineers within 24-48 hours. Once you select your candidate or team, we can have them fully onboarded and ready to integrate into your project within 48 to 72 hours. This allows you to avoid weeks or months of traditional hiring delays.
The difference is the ecosystem of support and accountability. A freelancer provides a single resource. We provide a comprehensive, managed solution. This includes dedicated project management, integrated quality assurance, ISO-certified security infrastructure, HR and IT support, and our free-replacement guarantee. You get a reliable, scalable, and secure partnership that de-risks your project, which is a level of infrastructure and certainty a freelancer cannot offer.