How Alexander Battery Technologies helped a Norwegian company transfer an established design into volume battery pack production.
A Norwegian subsea technology company approached Alexander Battery Technologies to explore manufacturing battery packs for one of their subsea sensors.
While the customer held an established battery design, they required an European manufacturing partner capable of reviewing production readiness, identifying supply-chain risks, managing regulatory pathways, and building a scalable manufacturing process around the product.
Following a detailed commercial and technical evaluation, including a visit to ABT’s manufacturing facility in North-East England, the customer formally qualified Alexander Battery Technologies as an approved supplier.
| Sector | Marine geophysics and subsea technology |
|---|---|
| Application | Subsea Sensor |
| Challenge | Transferring an established battery pack design into a controlled high-volume production environment |
| Service | Build-to-print battery pack manufacturing, with production transfer and volume manufacturing, with engineering, supply chain, and regulatory support. |
| Regulatory Scope | UN38.3 lithium battery transport testing and submission coordination. |
| Timescale | First production packs completed within 12 weeks, followed by phased programme delivery. |
We required a manufacturing partner to industrialise and produce battery packs for its sensors. Time to market was critical, meaning the chosen partner needed to move swiftly into validation and manufacturing while maintaining strict quality control for a demanding subsea application.
European manufacture was also a priority, giving the customer closer access to its production partner and greater visibility of the systems and people responsible for manufacturing its product.
Rather than treating it as a straightforward build-to-print project, our engineering and supply chain teams conducted an early review of the product to mitigate risk before manufacturing began.
We evaluated their proposed cell options and advised selecting a cell already established in production. This practical recommendation avoided introducing additional programme risk associated with a newer, unproven alternative. Simultaneously, the supply-chain team identified long-lead material risks early, allowing potential bottlenecks to be addressed well ahead of production start dates.
To streamline the regulatory pathway, ABT coordinated the UN38.3 transport testing process, advising on testing routes to optimise both cost and lead time. In parallel, our manufacturing team developed a tailored industrialisation process and phased delivery plan aligned directly with the customer’s assembly schedule.
A visit to our Peterlee facility enabled the team to review our quality systems, technical capabilities and our training firsthand, resulting in ABT’s formal supplier qualification.
A representative from the firm said:
“We truly appreciated the transparency and the engaging discussions during and after our visit. It was great to see the quality system you have in place.
“ABT scored highly on the areas that matter most to us, including manufacturing capabilities, quality systems and standards, traceability and transparency, employee training and education programmes, engineering capabilities and, importantly, a strong sense of ownership in clients’ products.”
The first production battery packs were completed within 12 weeks of the order being awarded, followed by a phased delivery schedule.
Throughout the programme, our engineering, supply chain and manufacturing teams worked closely together to manage component availability, production capacity and delivery requirements as the project progressed.
The full programme was delivered within eight months from order receipt, establishing a repeatable manufacturing route for the battery pack.
The project demonstrated ABT’s ability to transfer an established battery design into controlled European volume manufacture while providing comprehensive engineering, supply-chain, regulatory, and production support throughout the programme.
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