Prototyping & Production
Whether you need a quick functional prototype or a fully validated production batch, our integrated engineering and manufacturing workflow ensures accuracy, safety, and efficiency at every step. With 22+ years of experience in custom lithium battery development, we deliver professional-grade prototypes and scalable production for consumer, industrial, and medical applications.
Rapid Prototyping
Our rapid prototyping process bridges the gap between engineering design and production-ready battery packs. We turn conceptual requirements into functional samples for evaluation, verification, and testing.
What We Deliver in Prototyping:
Cell selection based on electrical & thermal performance, PCM/BMS configuration and firmware tuning, mechanical fitment prototypes (shrink-wrap, enclosure, connector), wiring, harness, and connector routing, functional validation samples (EVT), safety and electrical reliability checks.
Each prototype is produced using production-grade tools to ensure consistency between sample and mass production units.
Prototype Objectives:
Validate electrical performance, confirm thermal stability, verify mechanical fit & structural integrity, confirm system compatibility, evaluate cycle life & safety behavior.
We help your team quickly move from design requirements to real-world evaluation.
Engineering Verification & Testing
Every prototype undergoes rigorous validation to ensure it meets electrical, mechanical, thermal, and safety requirements before entering production.
Electrical Testing
Capacity, impedance, cycle life, discharge behavior at different loads, charging stability under CC/CV profile, BMS protection triggering, communication protocol validation (SMBus / I2C / UART / CAN).
Mechanical Testing
Vibration & shock, drop and impact resistance, connector retention & pull force testing, mechanical fit & enclosure stress test.
Environmental Testing
-20°C to 60°C operational stress test, environmental chamber cycling, humidity & thermal cycling.
Safety Validation
PCB/PCM/BMS protection accuracy, thermal runaway prevention, short-circuit tolerance, compliance pre-screening (UL2054, IEC62133, UN38.3, etc).
Pilot Run
Pilot runs are essential to validate manufacturability, process stability, and quality control consistency before mass production.
DVT – Design Verification Test
Structure reinforcement, cell matching & grading validation, assembly repeatability check, connector and harness durability, thermal dissipation verification.
PVT – Production Verification Test
Full production workflow simulation, production takt-time assessments, quality control sampling, packaging & logistics test, aging & final inspection process verification.
Pilot production ensures your battery pack can be manufactured reliably at scale with minimal variation.
Mass Production
With decades of combined industry experience, our production teams manufacture battery packs with strict process control and consistent reliability.
Manufacturing Capabilities
High-precision spot welding & laser welding, automated cell sorting & matching, real-time BMS flashing & calibration, semi-automated & fully automated assembly lines, high-temperature & low-temperature forming.
Quality Assurance
Incoming material inspection, in-process QC checkpoints, final functional testing (100% testing), aging test for enhanced reliability, statistical sampling & batch traceability.
Production Strengths
Low failure rate, stable output at scale, strong supply chain & material control, suitable for B2B long-term repeat orders, supports OEM / ODM labeling & packaging.
We deliver consistent, repeatable quality for every production batch—from hundreds of units to tens of thousands.
Packaging, Certification & Logistics
We support full downstream workflows, ensuring your battery packs are compliant, safely shipped, and ready for integration.
Packaging & Handling
Protective packaging design, custom labeling & branding, anti-static & fire-resistant packaging options.
Certification Support
UN38.3 transportation test, IEC62133 pre-evaluation, UL2054/UL1642 support, MSDS, test reports, and compliance documentation.
Logistics
Global shipping for lithium batteries, air / sea / express / DDP solutions, dangerous goods handling expertise.
All battery packs produced in our facilities follow strict engineering and manufacturing standards, ensuring long-term stability, consistent performance, and dependable safety. Whether you need rapid prototyping, pilot production, or scalable mass manufacturing, we provide end-to-end solutions with full traceability and professional engineering support.