Every additional vehicle we support started as a project on a bench: a vehicle pack pulled apart, measured, modelled, re-engineered and then driven. This is the work that turns a car we have never seen into a part number you can order.
What our engineers work on
Cell and module engineering
Characterising new cells from each supplier, defining the matching rules, and deciding which batches meet the traction spec.
BMS and firmware
Board-level repair, parameter and balance strategy work, and making a new pack talk to the vehicle the way the original did.
Thermal and mechanical design
Airflow and ducting, mounting and vibration behaviour, enclosure strength, and the sealing that keeps a pack alive in a wet climate.
Adding a new vehicle model
- Teardown and measurement – vehicle pack documented: module layout, cell format, BMS topology, cooling path and mounting points.
- Failure analysis – we establish how these packs actually fail in service, because that determines what a new build has to get right.
- Build definition – cell spec, matching rules, the components we replace, and a test protocol written for that specific model.
- Bench validation – prototype packs cycled, thermally stressed and run on the rig until the numbers hold.
- Road trial – fitted to a vehicle and driven for a set distance with data logged, before the part number is released.
- Release – build sheet, test limits and documentation set published, and the model added to the catalogue.
Specialist work
- High and low temperature operation – packs for cold climates and for hot ones, with charge and discharge windows set accordingly.
- Capacity upgrades – higher-energy module configurations where the enclosure and BMS allow it.
- Multi-chemistry builds – NiMH, lithium-ion and sodium-ion packs on the same line.
- Customer-specified designs – enclosure, connector, firmware and documentation developed to your brief under your brand.
Validation before release
Nothing reaches the catalogue on a promising prototype. A new part number carries the same test protocol as the rest of the range: capacity and resistance measurement, insulation and safety checks, thermal cycling and an ageing period, all recorded against serial numbers before release.
Develop with us
If you need a pack that does not exist yet — a different capacity, a different case, your own firmware parameters or your own documentation set — that is a development project rather than an order. See ODM & OEM, or send us the specification and we will tell you what is realistic and how long it takes.