Your Trusted E-Bike Battery Manufacturer

We are more than a supplier - we go above and beyond, becoming a strategic partner in performance, design, and long-term success.

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Introduction

Solution

Key Highlights

Our Capabilities

Lithium – ion: the go-to chemistry for E-bike battery packs

The 2000s were an important decade for the development of e-bikes as a viable product for consumers. At the start of the decade, electric bicycles, which can also be referred to as a pedelec, came equipped with either a lead-acid battery or a nickel-metal hydride pack, both of which were heavy, had a short lifespan, and had a low capacity. For the bike itself, this resulted in lower range and lower speeds, not good for consumer adoption. At the end of the decade, lithium battery packs were being adopted by OEMs, resulting in a lighter battery pack that provided increased ranges and speeds for users, who were finally seeing the potential of electric bikes. Moving into the 2020s, lithium batteries were standard, with OEMs turning to custom battery packs to get ahead of their competition. This move to lithium chemistry made the battery lighter whilst providing higher energy density and faster charging, resulting in increased usability, range and speeds making the bike more practical and therefore appealing for consumers.

How can OEMs use battery packs as a differentiator

OEMs are facing the challenge of how to stand out in a saturated market. Many pedelecs come equipped with a standard off-the-shelf (OTS) solution that lacks advanced features that would make their product stand out. In general, the basic off-the-shelf solution offers a low range, long charge time and limited smart technology features. The OEM surrenders design control owing to the battery’s specific shape, leading to a crowded market of bikes with similar frame architecture, similar performance, and little innovation. Price is the only differential in these market conditions, resulting in OEMs bringing their prices down to gain an edge over their competition.

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Custom battery packs that provide a competitive edge

A custom design gives OEMs freedom. There are plenty of choices an OEM can make with their pack design. By choosing higher energy density cells and optimising their placement, OEMs can extend bike range, maintain frame fit, and unlock unique designs with powerful performance. A custom battery pack manufacturer can optimise the weight and placement of the battery to enhance rider comfort, leading to greater user satisfaction, all of which can be determined early in the design phase. Custom battery solutions allow OEMs to decide on the interactive features they want built into their battery solution, such as drive systems and third-party accessories providing their product with another unique feature to enable them to stand out. A custom battery pack can be designed from scratch providing allowing manufacturers to chose whether to make their pack; lighter, faster, easier to use or to make it safer compared to their competition. Discover more from our e-bike expert, who discusses why bespoke battery packs provide an advantage to an OEM over an OTS solution.

How can ABT support your current and future e-bike battery manufacturing

At ABT, we want to be more than just a supplier; we want to be your strategic partner. For us, that means supporting you with your current projects whilst preparing for future battery requirements. We have 40 years of experience building innovative packs for tier-1 OEMs delivering over 15 million custom battery packs in this time. At our UK Battery manufacturing headquarters, we have the capacity to design and manufacture your perfect custom battery pack. Using our expertise in the e-bike field we work alongside our customers to deliver ultra-lightweight packs that are capable of delivering a high-power output to provide market-leading range.

As your strategic partner ABT will guide you through the end to end process of developing your custom battery pack. A huge part of this is designing a pack alongside our customers to guarantee it will pass regulatory requirements. As well as the standard UN 38.3 e-bike batteries will need to pass region specific regulations such as UL2271 and UL 2849 for Us customers and EN 15194 and EN 50604-1 for EU based OEMs. ABT will also assist our customers with any desired certifications such as IP, ISO or IEC certifications. We design our packs to be able to pass all the regulatory requirements our customer needs enabling them to sell their product worldwide.

e-bike battery pack

Start your custom battery pack project today.

Are you responsible for sourcing or developing battery solutions at an OEM and looking for a manufacturing partner?

We specialise in designing and manufacturing custom battery packs for manufacturers with high-volume production. Please note that we are unable to provide quotations for one-off requests or for replacement batteries in consumer goods.

Ready to move your battery project forward? Our experts can guide you through design, compliance, and production.

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