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Manufacturing That Eliminates Risk & Improves Reliability
Challenges Designing and Manufacturing
Lithium-Ion Battery Packs
5.12.23
Manufacturing That Eliminates Risk & Improves Reliability
2
Agenda
 Benefits and downsides of using an off-the-shelf battery
vs. custom.
 How to define a custom battery’s requirements.
 How and where should these custom batteries be
manufactured.
 How much time is needed to develop and get a custom
battery on the market?
Manufacturing That Eliminates Risk & Improves Reliability
3
Benefits and Downsides of Using an Off-the-shelf
Battery vs. Custom
Manufacturing That Eliminates Risk & Improves Reliability
4
Benefits of Using an Off-the-Shelf Battery
 Cost-effective:
– Off-the-shelf batteries are mass-produced, which makes them more cost-effective
than custom batteries.
 Availability:
– Off-the-shelf batteries are readily available and can be purchased in large
quantities, which can help meet production deadlines.
 Established standards:
– Off-the-shelf batteries are designed to meet established industry standards and
regulations, which can simplify the regulatory compliance process.
 Ease of integration:
– Using an off-the-shelf battery can be easier and faster than designing a custom
battery, as the integration process may be simpler.
Manufacturing That Eliminates Risk & Improves Reliability
5
Downsides of Using an Off-the-Shelf Battery
 Limited customization:
– The customization options for an off-the-shelf battery may be limited, which can
limit its performance and features.
 Compatibility issues:
– An off-the-shelf battery may not be compatible with all devices or systems, which
can result in compatibility issues.
 Intellectual property:
– An off-the-shelf battery might be a proprietary type design. You may not have
access to its design, nor the quality of materials used.
– Changes can happen without notice.
 Quality control:
– The quality of an off-the-shelf battery can vary depending on the manufacturer,
which can impact its performance, reliability and your product’s reputation.
Manufacturing That Eliminates Risk & Improves Reliability
6
Benefits of Using a Custom Battery Pack
 Tailored to meet specific requirements:
– A custom battery can be designed to meet specific requirements, which may not be
possible with an off-the-shelf battery. This can result in better performance, longer
life, and lower cost.
 Greater control over the design:
– With a custom battery, the design can be fine-tuned to optimize for specific
characteristics, such as size, weight, power output, and energy density.
– Component traceability
 Unique features can be designed in:
– A custom battery can have unique features such as multiple charging options,
longer life cycle, and advanced communication and interface protocols.
– Ability to optimize performance.
– Add counterfeit protection
Manufacturing That Eliminates Risk & Improves Reliability
7
Downsides of Using a Custom Battery Pack
 Higher cost:
– The cost of designing and manufacturing a custom battery can be much higher than
buying an off-the-shelf battery, which can be significant, particularly for low-volume
production runs.
 Longer development time:
– Developing a custom battery can be a time-consuming process, which can delay
the product launch.
 Requires specialized expertise:
– Designing a custom battery requires specialized knowledge and expertise, which
may not be available in-house.
 Manufacturing challenges:
– Manufacturing a custom battery can be a challenge as it requires a specialized
manufacturing process and custom test equipment to test unique features.
Manufacturing That Eliminates Risk & Improves Reliability
8
How to Define a Custom Battery’s Requirements
Manufacturing That Eliminates Risk & Improves Reliability
9
Once it is Determined That a Custom battery is Required,
Specifications Need be Clearly Defined
 Battery chemistry selection
 Cell selection and sourcing
 Battery capacity and voltage requirements
 Battery shape and size constraints
 Thermal management
 Safety features
 Firmware integration
– communication protocols
 Design Verification and testing
 Safety certifications and regulations
 Supply chain management
 Cost
Manufacturing That Eliminates Risk & Improves Reliability
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Battery Chemistry Selection
 Different chemistries offer varying
tradeoffs in terms of performance,
safety, and cost.
 Choose a chemistry that balances
the needs of the application, such as
energy density and power output.
Epec 2020 Webinar:
DO YOU REALLY NEED LITHIUM
OR WILL NICKEL METAL HYDRIDE
SUFFICE? Epec 2019 Webinar:
DESIGN CONSIDERATIONS
FOR LITHIUM BATTERIES
USED IN PORTABLE
DEVICES
Manufacturing That Eliminates Risk & Improves Reliability
11
Cell Selection and Sourcing
 Cells from different
manufacturers have varying
characteristics in terms of
capacity, energy density, and
safety.
 Selection of cells and suppliers
must consider quality, reliability,
and cost.
Epec 2015 Webinar:
HOW MANY CYCLES CAN I
EXPECT FROM MY
BATTERY?
Manufacturing That Eliminates Risk & Improves Reliability
12
Battery Capacity and Voltage Requirements
 Choosing the right cell chemistry and configuration.
 Calculating the capacity and voltage requirements
for the application.
 Battery pack voltage, capacity, and discharge rates
must match the requirements of the application.
 Protection circuits must be included to prevent
overcharging, over-discharging, and short-
circuiting.
Manufacturing That Eliminates Risk & Improves Reliability
13
Battery Shape and Size Constraints
 Designing the battery to fit within the space constraints of the
application.
 Optimizing the battery shape for ease of integration.
Manufacturing That Eliminates Risk & Improves Reliability
14
Thermal Management
 Managing temperature during
charging, discharging, and storage.
– Paying close attention to thermal
gradients.
 Incorporating temperature sensors
and controls.
Manufacturing That Eliminates Risk & Improves Reliability
15
Safety Features
 Implement overcharge and over-discharge protection.
– Safety circuits with voltage detection and FET integration.
– Secondary protection on medical batteries.
 Incorporate short circuit and overcurrent protection.
– Quick-acting AFE FET protection.
– Fuse.
 Incorporate thermal runaway protection.
– Cell spacing.
– Thermal fuses.
Epec 2017 Webinar:
ALTERNATIVES TO
CHEMICAL FUSES IN
BATTERY SECONDARY
SAFETY CIRCUITS
Manufacturing That Eliminates Risk & Improves Reliability
16
Firmware Integration and Communication Protocols
 Establishing communication protocols for battery monitoring and
control.
– I2C
– SMBus
– CAN Bus
– Full custom
 Ensuring proper operation and communication between the battery
and host system.
Manufacturing That Eliminates Risk & Improves Reliability
17
Design Verification and Testing
 Verify that all specified
requirements have been
met by conducting thorough
testing to ensure battery
works within defined
parameters
 System level testing is done
by the customer with Epec’s
input
Manufacturing That Eliminates Risk & Improves Reliability
18
Design Verification and Testing
 Mechanical testing:
– This type of testing evaluates the battery's physical properties such as its
strength, durability, and resistance to impact and vibration. Examples of
mechanical tests include drop testing, compression testing, and shock
testing.
 Electrical testing:
– This type of testing measures the battery's electrical characteristics, such
as voltage, current, capacity, and resistance. Examples of electrical tests
include open circuit voltage (OCV) measurement, charge and discharge
testing, and cycling testing.
Manufacturing That Eliminates Risk & Improves Reliability
19
Design Verification and Testing
 Environmental testing:
– This type of testing evaluates the battery's performance and safety under
various environmental conditions, such as temperature, humidity, and
altitude. Examples of environmental tests include thermal cycling, high-
temperature storage, and humidity testing.
 Safety testing:
– This type of testing assesses the battery's safety features, such as its
ability to prevent overcharging, over-discharging, and short-circuiting.
Examples of safety tests include overcharge testing, over-discharge
testing, and short-circuit testing.
Manufacturing That Eliminates Risk & Improves Reliability
20
Safety Certifications and Regulations
 Ensuring compliance with safety regulations and standards.
 Battery design and manufacturing must comply with industry and
government regulations, such as UL 2054 and IEC 62133.
 Compliance with environmental regulations such as RoHS and
REACH is also necessary.
Epec 2021 Webinar:
BATTERY PACKS FOR
MEDICAL DEVICES:
REQUIREMENTS AND
CERTIFICATION Epec 2016 Webinar:
LITHIUM BATTERY
REGULATIONS & HOW THEY
AFFECT OEM'S
Manufacturing That Eliminates Risk & Improves Reliability
21
Supply Chain Management
 Sourcing high-quality components.
 Ensuring component availability and reliability.
 Reduce the use of custom highly-integrated ICs.
 Identify these parts and use the Silicon Expert website for crosses:
siliconexpert.com.
Manufacturing That Eliminates Risk & Improves Reliability
22
Cost
 Balancing cost and performance requirements.
 Reducing costs through optimized design and efficient manufacturing.
• The battery design can have a significant impact on its cost.
– Reduce the amount of material and parts required.
– Simplify the manufacturing process.
• For example: Reducing the number of cells in the battery pack or optimizing
the cell arrangement can lower the cost of materials and simplify the assembly
process. Avoiding custom contacts, harnesses, number of custom plastic
parts… can reduce both NRE and recurring product costs.
Manufacturing That Eliminates Risk & Improves Reliability
23
How and Where Should These
Custom Batteries Be Manufactured
Manufacturing That Eliminates Risk & Improves Reliability
24
In-house Manufacturing vs. Outsourcing
 In-house manufacturing can offer
more control over the process, but it
can also require significant capital
investment in equipment, facilities,
and skilled labor.
 Outsourcing can be more cost-
effective, but it requires careful
selection of a reliable CM with
experience in battery manufacturing.
Manufacturing That Eliminates Risk & Improves Reliability
25
Manufacturing Location
 The location of the manufacturing facility can impact the cost of
production and the speed of delivery.
– Offshore: Lower cost, less-complicated batteries.
– Domestic: Higher tech, medical, and military batteries.
Manufacturing That Eliminates Risk & Improves Reliability
26
Production Capital Expenses
 The capital expense required for manufacturing custom batteries can
vary significantly depending on the scale of production, the complexity
of the battery design, and the level of automation.
 Some of the major expenses include:
– Equipment for cell assembly into battery packs.
– Custom programming and test fixtures.
– Packaging, and specialized tooling.
Manufacturing That Eliminates Risk & Improves Reliability
27
Supply Chain Issues
 Lithium-ion battery production involves sourcing raw materials and
components from suppliers around the world.
 Issues such as supply chain disruptions, price fluctuations, and quality
control can affect the availability and cost of these materials, which
can impact the production schedule and cost of the batteries.
Epec 2022 Webinar:
DEALING WITH COMPONENT
SHORTAGES THAT IMPACT
BATTERY PACKS DESIGNS
Manufacturing That Eliminates Risk & Improves Reliability
28
Supply Chain Issues
 Lithium-ion battery production involves sourcing raw materials and
components from suppliers around the world.
 Issues such as supply chain disruptions, price fluctuations, and quality
control can affect the availability and cost of these materials, which
can impact the production schedule and cost of the batteries.
Epec 2022 Webinar:
DEALING WITH COMPONENT
SHORTAGES THAT IMPACT
BATTERY PACKS DESIGNS
Manufacturing That Eliminates Risk & Improves Reliability
29
How Much Time is Needed to Develop and Get a
Custom Battery on the Market?
Manufacturing That Eliminates Risk & Improves Reliability
30
Development Time
 The time required to develop and bring a custom battery to market can
vary significantly depending on various factors.
– Such as the complexity of the battery design.
– The level of customization required.
– The availability of raw materials and components.
– The regulatory requirements in the target market.
Manufacturing That Eliminates Risk & Improves Reliability
31
Development Time
 Overall, the development and
commercialization of a custom battery can
take anywhere from 6 months to 2 years,
depending on the complexity of the design
and the level of customization required.
– It is important to factor in these timelines
when planning for the development and
launch of a custom battery product.
Epec 2014 Webinar:
BATTERY PACK
DEVELOPMENT TIMELINE
WEBINAR
Manufacturing That Eliminates Risk & Improves Reliability
32
Design and Engineering Timeline Elements
 The design phase involves:
– Defining the requirements of the battery.
– Selecting the appropriate cell configuration and chemistry.
– Designing the protection circuit.
– Enclosure, and electronics, and testing the prototypes.
 The time required for this phase can range from a few weeks to
several months, depending on the complexity of the battery design
and the level of customization required.
Manufacturing That Eliminates Risk & Improves Reliability
33
Tooling and Equipment Timeline Elements
 Once the battery design is finalized:
– Specialized tooling and equipment need
to be developed or purchased to
produce the battery cells and assemble
the final product.
 This phase can take several weeks to
several months, depending on the
availability of the required equipment
and the complexity of the
manufacturing process.
Manufacturing That Eliminates Risk & Improves Reliability
34
Manufacturing and Testing Timeline Elements
 This phase involves the actual production
of the batteries:
– Assembly of the final product.
– Testing to ensure that the batteries meet
the required performance per the
specifications.
 The time required for this phase can vary
depending on the scale of production, the
level of automation, and the complexity of
the testing process.
Manufacturing That Eliminates Risk & Improves Reliability
35
Certification and Compliance Timeline Elements
 Depending on the target market and the intended use of the battery,
various certifications and compliance requirements may need to be
met before the product can be launched. This can include:
– Safety certifications.
– Environmental regulations.
– International standards.
 The time required for this phase can vary depending on the regulatory
requirements and the complexity of the certification process.
Manufacturing That Eliminates Risk & Improves Reliability
36
Summary
Manufacturing That Eliminates Risk & Improves Reliability
37
Summary
 We looked at the benefits and downsides of using an off-the-shelf
battery vs. developing a custom battery…many factors to consider.
 Defining the custom battery’s requirements to minimize development
costs and time to market is critical.
 Knowing how and where the custom battery should be manufactured
is important for quality, cost, and control reasons.
 A custom battery can take anywhere from six months to two years,
depending on the complexity of the design and the level of
customization required.
Manufacturing That Eliminates Risk & Improves Reliability
38
Our Products
Battery Packs Flex & Rigid-Flex PCBs Cable Assemblies Printed Circuit Boards
CNC Machining User Interfaces Flexible Heaters EC Fans & Motors
Manufacturing That Eliminates Risk & Improves Reliability
39
Q&A
 Questions?
– Enter any questions you may have
in the control panel
– If we don’t have time to get to it, we
will reply via email
Manufacturing That Eliminates Risk & Improves Reliability
40
Thank You
Check out our website at www.epectec.com.
For more information email sales@epectec.com.
Stay Connected with Epec Engineered Technologies
Follow us on our social media sites for continuous technical updates and information:

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Challenges Designing and Manufacturing Lithium-Ion Battery Packs

  • 1. Manufacturing That Eliminates Risk & Improves Reliability Challenges Designing and Manufacturing Lithium-Ion Battery Packs 5.12.23
  • 2. Manufacturing That Eliminates Risk & Improves Reliability 2 Agenda  Benefits and downsides of using an off-the-shelf battery vs. custom.  How to define a custom battery’s requirements.  How and where should these custom batteries be manufactured.  How much time is needed to develop and get a custom battery on the market?
  • 3. Manufacturing That Eliminates Risk & Improves Reliability 3 Benefits and Downsides of Using an Off-the-shelf Battery vs. Custom
  • 4. Manufacturing That Eliminates Risk & Improves Reliability 4 Benefits of Using an Off-the-Shelf Battery  Cost-effective: – Off-the-shelf batteries are mass-produced, which makes them more cost-effective than custom batteries.  Availability: – Off-the-shelf batteries are readily available and can be purchased in large quantities, which can help meet production deadlines.  Established standards: – Off-the-shelf batteries are designed to meet established industry standards and regulations, which can simplify the regulatory compliance process.  Ease of integration: – Using an off-the-shelf battery can be easier and faster than designing a custom battery, as the integration process may be simpler.
  • 5. Manufacturing That Eliminates Risk & Improves Reliability 5 Downsides of Using an Off-the-Shelf Battery  Limited customization: – The customization options for an off-the-shelf battery may be limited, which can limit its performance and features.  Compatibility issues: – An off-the-shelf battery may not be compatible with all devices or systems, which can result in compatibility issues.  Intellectual property: – An off-the-shelf battery might be a proprietary type design. You may not have access to its design, nor the quality of materials used. – Changes can happen without notice.  Quality control: – The quality of an off-the-shelf battery can vary depending on the manufacturer, which can impact its performance, reliability and your product’s reputation.
  • 6. Manufacturing That Eliminates Risk & Improves Reliability 6 Benefits of Using a Custom Battery Pack  Tailored to meet specific requirements: – A custom battery can be designed to meet specific requirements, which may not be possible with an off-the-shelf battery. This can result in better performance, longer life, and lower cost.  Greater control over the design: – With a custom battery, the design can be fine-tuned to optimize for specific characteristics, such as size, weight, power output, and energy density. – Component traceability  Unique features can be designed in: – A custom battery can have unique features such as multiple charging options, longer life cycle, and advanced communication and interface protocols. – Ability to optimize performance. – Add counterfeit protection
  • 7. Manufacturing That Eliminates Risk & Improves Reliability 7 Downsides of Using a Custom Battery Pack  Higher cost: – The cost of designing and manufacturing a custom battery can be much higher than buying an off-the-shelf battery, which can be significant, particularly for low-volume production runs.  Longer development time: – Developing a custom battery can be a time-consuming process, which can delay the product launch.  Requires specialized expertise: – Designing a custom battery requires specialized knowledge and expertise, which may not be available in-house.  Manufacturing challenges: – Manufacturing a custom battery can be a challenge as it requires a specialized manufacturing process and custom test equipment to test unique features.
  • 8. Manufacturing That Eliminates Risk & Improves Reliability 8 How to Define a Custom Battery’s Requirements
  • 9. Manufacturing That Eliminates Risk & Improves Reliability 9 Once it is Determined That a Custom battery is Required, Specifications Need be Clearly Defined  Battery chemistry selection  Cell selection and sourcing  Battery capacity and voltage requirements  Battery shape and size constraints  Thermal management  Safety features  Firmware integration – communication protocols  Design Verification and testing  Safety certifications and regulations  Supply chain management  Cost
  • 10. Manufacturing That Eliminates Risk & Improves Reliability 10 Battery Chemistry Selection  Different chemistries offer varying tradeoffs in terms of performance, safety, and cost.  Choose a chemistry that balances the needs of the application, such as energy density and power output. Epec 2020 Webinar: DO YOU REALLY NEED LITHIUM OR WILL NICKEL METAL HYDRIDE SUFFICE? Epec 2019 Webinar: DESIGN CONSIDERATIONS FOR LITHIUM BATTERIES USED IN PORTABLE DEVICES
  • 11. Manufacturing That Eliminates Risk & Improves Reliability 11 Cell Selection and Sourcing  Cells from different manufacturers have varying characteristics in terms of capacity, energy density, and safety.  Selection of cells and suppliers must consider quality, reliability, and cost. Epec 2015 Webinar: HOW MANY CYCLES CAN I EXPECT FROM MY BATTERY?
  • 12. Manufacturing That Eliminates Risk & Improves Reliability 12 Battery Capacity and Voltage Requirements  Choosing the right cell chemistry and configuration.  Calculating the capacity and voltage requirements for the application.  Battery pack voltage, capacity, and discharge rates must match the requirements of the application.  Protection circuits must be included to prevent overcharging, over-discharging, and short- circuiting.
  • 13. Manufacturing That Eliminates Risk & Improves Reliability 13 Battery Shape and Size Constraints  Designing the battery to fit within the space constraints of the application.  Optimizing the battery shape for ease of integration.
  • 14. Manufacturing That Eliminates Risk & Improves Reliability 14 Thermal Management  Managing temperature during charging, discharging, and storage. – Paying close attention to thermal gradients.  Incorporating temperature sensors and controls.
  • 15. Manufacturing That Eliminates Risk & Improves Reliability 15 Safety Features  Implement overcharge and over-discharge protection. – Safety circuits with voltage detection and FET integration. – Secondary protection on medical batteries.  Incorporate short circuit and overcurrent protection. – Quick-acting AFE FET protection. – Fuse.  Incorporate thermal runaway protection. – Cell spacing. – Thermal fuses. Epec 2017 Webinar: ALTERNATIVES TO CHEMICAL FUSES IN BATTERY SECONDARY SAFETY CIRCUITS
  • 16. Manufacturing That Eliminates Risk & Improves Reliability 16 Firmware Integration and Communication Protocols  Establishing communication protocols for battery monitoring and control. – I2C – SMBus – CAN Bus – Full custom  Ensuring proper operation and communication between the battery and host system.
  • 17. Manufacturing That Eliminates Risk & Improves Reliability 17 Design Verification and Testing  Verify that all specified requirements have been met by conducting thorough testing to ensure battery works within defined parameters  System level testing is done by the customer with Epec’s input
  • 18. Manufacturing That Eliminates Risk & Improves Reliability 18 Design Verification and Testing  Mechanical testing: – This type of testing evaluates the battery's physical properties such as its strength, durability, and resistance to impact and vibration. Examples of mechanical tests include drop testing, compression testing, and shock testing.  Electrical testing: – This type of testing measures the battery's electrical characteristics, such as voltage, current, capacity, and resistance. Examples of electrical tests include open circuit voltage (OCV) measurement, charge and discharge testing, and cycling testing.
  • 19. Manufacturing That Eliminates Risk & Improves Reliability 19 Design Verification and Testing  Environmental testing: – This type of testing evaluates the battery's performance and safety under various environmental conditions, such as temperature, humidity, and altitude. Examples of environmental tests include thermal cycling, high- temperature storage, and humidity testing.  Safety testing: – This type of testing assesses the battery's safety features, such as its ability to prevent overcharging, over-discharging, and short-circuiting. Examples of safety tests include overcharge testing, over-discharge testing, and short-circuit testing.
  • 20. Manufacturing That Eliminates Risk & Improves Reliability 20 Safety Certifications and Regulations  Ensuring compliance with safety regulations and standards.  Battery design and manufacturing must comply with industry and government regulations, such as UL 2054 and IEC 62133.  Compliance with environmental regulations such as RoHS and REACH is also necessary. Epec 2021 Webinar: BATTERY PACKS FOR MEDICAL DEVICES: REQUIREMENTS AND CERTIFICATION Epec 2016 Webinar: LITHIUM BATTERY REGULATIONS & HOW THEY AFFECT OEM'S
  • 21. Manufacturing That Eliminates Risk & Improves Reliability 21 Supply Chain Management  Sourcing high-quality components.  Ensuring component availability and reliability.  Reduce the use of custom highly-integrated ICs.  Identify these parts and use the Silicon Expert website for crosses: siliconexpert.com.
  • 22. Manufacturing That Eliminates Risk & Improves Reliability 22 Cost  Balancing cost and performance requirements.  Reducing costs through optimized design and efficient manufacturing. • The battery design can have a significant impact on its cost. – Reduce the amount of material and parts required. – Simplify the manufacturing process. • For example: Reducing the number of cells in the battery pack or optimizing the cell arrangement can lower the cost of materials and simplify the assembly process. Avoiding custom contacts, harnesses, number of custom plastic parts… can reduce both NRE and recurring product costs.
  • 23. Manufacturing That Eliminates Risk & Improves Reliability 23 How and Where Should These Custom Batteries Be Manufactured
  • 24. Manufacturing That Eliminates Risk & Improves Reliability 24 In-house Manufacturing vs. Outsourcing  In-house manufacturing can offer more control over the process, but it can also require significant capital investment in equipment, facilities, and skilled labor.  Outsourcing can be more cost- effective, but it requires careful selection of a reliable CM with experience in battery manufacturing.
  • 25. Manufacturing That Eliminates Risk & Improves Reliability 25 Manufacturing Location  The location of the manufacturing facility can impact the cost of production and the speed of delivery. – Offshore: Lower cost, less-complicated batteries. – Domestic: Higher tech, medical, and military batteries.
  • 26. Manufacturing That Eliminates Risk & Improves Reliability 26 Production Capital Expenses  The capital expense required for manufacturing custom batteries can vary significantly depending on the scale of production, the complexity of the battery design, and the level of automation.  Some of the major expenses include: – Equipment for cell assembly into battery packs. – Custom programming and test fixtures. – Packaging, and specialized tooling.
  • 27. Manufacturing That Eliminates Risk & Improves Reliability 27 Supply Chain Issues  Lithium-ion battery production involves sourcing raw materials and components from suppliers around the world.  Issues such as supply chain disruptions, price fluctuations, and quality control can affect the availability and cost of these materials, which can impact the production schedule and cost of the batteries. Epec 2022 Webinar: DEALING WITH COMPONENT SHORTAGES THAT IMPACT BATTERY PACKS DESIGNS
  • 28. Manufacturing That Eliminates Risk & Improves Reliability 28 Supply Chain Issues  Lithium-ion battery production involves sourcing raw materials and components from suppliers around the world.  Issues such as supply chain disruptions, price fluctuations, and quality control can affect the availability and cost of these materials, which can impact the production schedule and cost of the batteries. Epec 2022 Webinar: DEALING WITH COMPONENT SHORTAGES THAT IMPACT BATTERY PACKS DESIGNS
  • 29. Manufacturing That Eliminates Risk & Improves Reliability 29 How Much Time is Needed to Develop and Get a Custom Battery on the Market?
  • 30. Manufacturing That Eliminates Risk & Improves Reliability 30 Development Time  The time required to develop and bring a custom battery to market can vary significantly depending on various factors. – Such as the complexity of the battery design. – The level of customization required. – The availability of raw materials and components. – The regulatory requirements in the target market.
  • 31. Manufacturing That Eliminates Risk & Improves Reliability 31 Development Time  Overall, the development and commercialization of a custom battery can take anywhere from 6 months to 2 years, depending on the complexity of the design and the level of customization required. – It is important to factor in these timelines when planning for the development and launch of a custom battery product. Epec 2014 Webinar: BATTERY PACK DEVELOPMENT TIMELINE WEBINAR
  • 32. Manufacturing That Eliminates Risk & Improves Reliability 32 Design and Engineering Timeline Elements  The design phase involves: – Defining the requirements of the battery. – Selecting the appropriate cell configuration and chemistry. – Designing the protection circuit. – Enclosure, and electronics, and testing the prototypes.  The time required for this phase can range from a few weeks to several months, depending on the complexity of the battery design and the level of customization required.
  • 33. Manufacturing That Eliminates Risk & Improves Reliability 33 Tooling and Equipment Timeline Elements  Once the battery design is finalized: – Specialized tooling and equipment need to be developed or purchased to produce the battery cells and assemble the final product.  This phase can take several weeks to several months, depending on the availability of the required equipment and the complexity of the manufacturing process.
  • 34. Manufacturing That Eliminates Risk & Improves Reliability 34 Manufacturing and Testing Timeline Elements  This phase involves the actual production of the batteries: – Assembly of the final product. – Testing to ensure that the batteries meet the required performance per the specifications.  The time required for this phase can vary depending on the scale of production, the level of automation, and the complexity of the testing process.
  • 35. Manufacturing That Eliminates Risk & Improves Reliability 35 Certification and Compliance Timeline Elements  Depending on the target market and the intended use of the battery, various certifications and compliance requirements may need to be met before the product can be launched. This can include: – Safety certifications. – Environmental regulations. – International standards.  The time required for this phase can vary depending on the regulatory requirements and the complexity of the certification process.
  • 36. Manufacturing That Eliminates Risk & Improves Reliability 36 Summary
  • 37. Manufacturing That Eliminates Risk & Improves Reliability 37 Summary  We looked at the benefits and downsides of using an off-the-shelf battery vs. developing a custom battery…many factors to consider.  Defining the custom battery’s requirements to minimize development costs and time to market is critical.  Knowing how and where the custom battery should be manufactured is important for quality, cost, and control reasons.  A custom battery can take anywhere from six months to two years, depending on the complexity of the design and the level of customization required.
  • 38. Manufacturing That Eliminates Risk & Improves Reliability 38 Our Products Battery Packs Flex & Rigid-Flex PCBs Cable Assemblies Printed Circuit Boards CNC Machining User Interfaces Flexible Heaters EC Fans & Motors
  • 39. Manufacturing That Eliminates Risk & Improves Reliability 39 Q&A  Questions? – Enter any questions you may have in the control panel – If we don’t have time to get to it, we will reply via email
  • 40. Manufacturing That Eliminates Risk & Improves Reliability 40 Thank You Check out our website at www.epectec.com. For more information email sales@epectec.com. Stay Connected with Epec Engineered Technologies Follow us on our social media sites for continuous technical updates and information: