OUR WELL-PROVEN PROCESS TO CREATING CUSTOM BATTERY PACKS

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Custom Battery Packs

Building a custom battery pack that is fit-for-purpose takes a team of technical experts, including mechanical and electrical engineers. Ultralife UK’s teams work closely together and liaise with your device designers from the outset to ensure that battery requirements are met.

This clear communication, coupled with well-proven project management processes, ensures that custom solutions are delivered in a timely and cost effective manner. Take a look at the steps that go into the process below:

Understand

Project Launch: 

Understand & collate customer requirements.
Authoring of detailed technical specification & ongoing maintenance of project documentation.

Design

Product Design: 

Detailed electrical & mechanical design of product (i.e. the battery pack).
May include the purchase of initial design proving components & bench testing.
May include EMC pre-compliance testing (w/o report & w/o certification).

Prototype

Prototype Build:

Fabrication of product (i.e. battery pack) parts using rapid prototype techniques.
Assembly & test of a small number of products (i.e. battery packs) using limited fixturing, Quantity of products sent to customer for evaluation (Dangerous Goods shipping required if the product is a Lithium battery).
Quantity of batteries retained by Ultralife UK for Design Validation (see below).

Validate

Design Validation:

Internal verification of product (i.e. the battery pack).
Creation of test plan against the technical specification & subsequent internal laboratory testing of prototypes against plan.
Authoring of validation report.
Excludes external regulatory qualification which is done during Regulatory Qualification (see below).

Tool

Tooling:

Hard tooling of product (i.e. battery pack) components which may include injection moulded plastics, formed metal parts, injection moulded metal parts, PCBAs, light pipes, packaging, labels, PCBAs, membrane panels etc (this is neither an inclusive nor an exhaustive list).
Includes tool trials (where appropriate) & shipping of tools from Asia to UK (where appropriate)

Build

Pre-Series Build:

Low volume build of non-qualified products (i.e. battery packs) using production tooled components.
Majority sent to customer for approval (Dangerous Goods shipping if a Lithium-ion battery), balance retained at Ultralife UK.

Fixture

Production Fixturing & Test:

Design & build of production jigs & fixtures, test equipment & software.
This allows us to assemble & test the product in a volume production environment

Qualify

Regulatory Qualification:

Purchase of components & assembly into products (i.e. battery packs) for regulatory qualification testing.
Including creation of necessary paperwork. Shipment of products (i.e. battery packs) to external test house for certification testing / reporting.
Tests can include UN 38.3 (transport), IEC 62133-2:2017 (safety), UL 62133-2 (safety), UL 2054 (safety), EMC, Ingress Protection testing, Environmental Testing, IEC 62368-1, UL 62368-1, RoHS, REACH, WEEE validation (this is neither an inclusive nor an exhaustive list)

Manufacture

New Product Introduction:

Generation of production documentation, training of operators, build of a small NPI batch.
Later sent to customer as a homologation batch, retained at Ultralife UK or scrapped.

Contact Ultralife UK

If you have a question for our battery experts in the UK, please complete the form on this page. Alternatively, please call us on +44 1782 566 688.

Ultralife UK
Unit 20 Loomer Road
Chesterton, Newcastle-under-Lyme
Staffordshire
ST5 7LB
United Kingdom

Office Hours (Time in UK)
Monday to Thursday: 0745 hrs to 1630 hrs
Friday: 0745 hrs to 1215 hrs
Saturday & Sunday: Closed

General Enquiries Tel: +44 (0) 1782 566622
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Technical Support Tel: +44 (0) 1782 566622

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If you are interested in our products and services please use the form below to contact us. Or call us on +44 1782 566688

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