Battery Pack Development
We are a full-service custom battery manufacturer. We design lithium battery packs according to your specifications with both design, engineering and manufacturing competences.
The process of making a new battery design always starts with a drawing and specification.
We work professionally with 3D CAD systems so as to always have a common reference and understanding of the project at hand.
Cell/module selection
Selecting the correct cell for a battery pack is crucial for optimal performance, manufacturability, and cost-effectiveness. Consider factors like energy density, capacity, voltage, and discharge rates, aligning with the application’s requirements. Safety, cycle life, and cost should also be evaluated to ensure an efficient and reliable battery pack.
Requirements
A battery pack’s technical requirements should encompass performance parameters like capacity, voltage, and power output. Include relevant safety standards for the end-application, thermal management requirements, and specify operating conditions, mechanical design, cycle life, and end-of-life expectations.
Structuring a requirements specification for a lithium battery pack is essential to ensure the safe and efficient operation of the battery system. The specification should be comprehensive and address various aspects related to the battery pack design, performance, and safety. Here are some key considerations for structuring the requirement specification:
Capacity, voltage, energy density and required charge and discharge rates.
Safety standards and regulations relevant to the battery and the end-application technology.
Specify the physical dimensions, weight limitations, and mechanical constraints for the battery pack
Set expectations for the battery’s cycle life, indicating the number of charge/discharge cycles it can endure before reaching end-of-life.
Address transportation and handling requirements, considering safety regulations and packaging guidelines.
State the expected warranty period and quality control procedures to assure reliable performance and end-customer satisfaction.
Outline the testing and validation procedures required during the development and manufacturing process to ensure the battery pack meets all specified requirements.
Specify the necessary documentation. reports, and certificates needed to demonstrate compliance with applicable standards and regulations.
Toolbox
Here are some examples of the areas we cover when developing new products.
These are just some of the tools in our “toolbox”.
Mechanical Design
- Enclosure
- Injection molding, laser welding, deep-drawing, etc.
- IP67 / water-proof design
- Portability
- Connectivity
Electrical Specifications
- Voltage
- Amperage
- Charging and discharging
- Capacity
- Longevity / Cycle-life
Communications
- CANBus
- Serial communication (RS232, RS485, UART)
- Wireless communication (GSM, BT, BTLE, WiFi)
- DC-Bus (CAN over DC)
Testing & Certification
- UN38.3, CE, RoHS
- IEC & UL standards
- ETL-marking
- CB Scheme
Packaging
- Custom graphics
- Custom UN-packaging
- UV laser printing
What We Do
Not 'just' a battery
We try to provide more than just a battery, by focusing on making solution that create/add value for users. We do this through innovation and close collaboration throughout the value chain.
From idea to mass production
From the first sketches to the finished packaged pallets – we make sure that everything runs smoothly.
100 units or 100.00 units
Small batches and large mass production volumes are equally welcome. We strive to deliver cost effective quality in either case.
4 week rapid prototyping
Our agile development approach enables us to deliver prototypes within a very short time-line.
Certification
We facilitate third-party testing and certification within a large scope of standards. Our in-depth knowledge of this area enables us to guide you through the regulatory maze.
Pack design
Design considerations for the mechanical design of a battery pack should address physical dimensions, weight, and integration with the application. Robust casing materials, such as fire-resistant plastics or metals, should be chosen to ensure protection against impacts and thermal management. The casing must also facilitate easy assembly and maintenance.
At WST we work with all types of materials and production processes such as casting, printing, milling, injection-molding and sheet-metal forming.
IP-rating
Heat barriers (Mica, Aerogel etc.)
Thermal management (passive/active)
Phase change material (PCM)
Early warning / Thermal runaway detection
BMS
The BMS monitors individual cell parameters to balance cells and prevent overcharging/over-discharging. Seamless data communication enhances battery efficiency. Functional safety features mitigate risks, ensuring reliable, durable, and secure battery pack.
