Battery pack design services

The best route depends on your technical requirements, regulatory needs, timelines and commercial volumes. Core, Core+ and TotalCustom each suit different levels of complexity, and the right choice often becomes clear once we understand your application and constraints.

Share your project details with us and our engineering team will guide you through the options and recommend the most suitable path.

Yes. We work with OEMs at early stages of product development to assess feasibility, define battery requirements and establish a clear route to production.

This typically involves supporting projects where there is a clear application, expected volumes and a commercial pathway. Our focus is on programmes that will progress to volume manufacture, rather than one-off or exploratory design work.

Our OEM battery design and manufacturing service covers every stage of your battery programme. From initial concept and design validation through compliance testing and full-series production at our UK facility. You’ll benefit from our in-house engineering expertise, complete traceability and a dedicated project team.

The time from battery concept through to production depends on the service chosen and the complexity of the battery design. For simple designs based on our Core platform, you can expect design through to full-production in as little as 6 months, while fully bespoke TotalCustom battery packs may take up to 24 months to enter series production.

The cheapest option is usually an off-the-shelf battery pack, as these are not specialised and are produced in high volumes. ABT offers different levels of customisation through its Core, Core+ and TotalCustom services, and costs scale depending on the level of non-recurring engineering (NRE) for design, testing and validation. More original or complex designs typically require higher NREs.

Yes! Alexander Battery Technologies provides a range of services suited to fit the level of modifications your existing design needs. This ranges from a few tweaks to a full re-design. Contact us to discuss your specific requirements.Contact us to discuss your specific requirements.

An experienced battery partner can help you to define which compliance and regulatory approvals are needed for your product and markets. Our battery design team is experienced in designing with common regulatory requirements such as IEC 62133, IEC 62619, and UN 38.3 in mind. Understanding these requirements up-front helps to ensure a first-time pass rate and avoid any costly redesigns or delays in project timelines. We support OEMs by dealing direct with test houses and coordinating the whole process. We provide pass-through costs without mark-up for these approvals.

ABT works with OEMs to develop and manufacture battery packs intended for mass production. If you’ve received working prototypes from another supplier and are now ready to scale, ABT can support with a build-to-print battery pack manufacturing for your existing design.

With over 40 years of experience in battery manufacturing, ABT has seen cell technology evolve significantly. We select the most suitable chemistry based on each project’s performance, safety and cost requirements, usually defined by the end application. Most of our projects centre on rechargeable lithium-ion (Li-ion) battery pack design, but we can also support Nickel-Metal Hydride (NiMH) technologies,Lithium-Iron Phosphate (LiFePO₄) and other specialist chemistries when appropriate.

Yes. This page replaces our previous battery pack design and assembly service and reflects how we now structure our services. We provide battery pack design that progresses into volume manufacturing, as well as build-to-print battery manufacturing for OEMs with an existing, production-ready design. Battery design is delivered as part of a route to manufacture, while build-to-print manufacturing can be delivered as a standalone service. Information about our battery pack assembly services are available here.