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Electric car lithium battery pack and power connections

Battery Pack Design & Assembly

The world is experiencing a critical shortage of battery engineers, but Treetown can help fill the gap. Our team has deep knowledge and extensive experience in designing batteries and their assembly processes.

A Powerful Partner

We specialize in every stage of battery development, from selecting the right cell chemistry and cell, to optimizing battery pack design for performance, longevity, and safety. Our engineers are experts in battery thermal management, ensuring that heat dissipation strategies like liquid cooling, phase-change materials, and active airflow keep cells operating at peak condition.

We also understand the extreme demands of rugged applications, whether it’s designing battery systems to withstand battlefield conditions for military use or ensuring reliable operation in aerospace, marine, or industrial environments. Our work includes ruggedizing enclosures, shock-proofing, and implementing fail-safes for extreme temperatures, vibration, and impact.

Beyond design, we obsess over quality and safety testing. Our team rigorously analyzes battery performance through FEA modeling, real-world stress testing, and compliance with industry standards like UN38.3, IEC 62133, and MIL-STD certifications. We develop advanced Battery Management Systems (BMS) that not only monitor cell health but also optimize charge cycles, prevent thermal runaway, and extend battery life.

Worker welding repair mold and die part by Laser welding machine in factory.
Treetown Tech employee welding metal

What We Design

Being solution-oriented, we are cell and design-agnostic and select optimal solutions for each application. By leveraging past product design and successes, we can build our experience into greater solutions in battery packs, module engineering, mechanical and electrical design, and ensure our rugged batteries can withstand abusive environments in military applications.

Types of Engineered Battery Prototypes

Contemporary batteries feature metallurgically-joined cell interconnections that are resistance welded or laser welded. Do you know what this means? That it's really cool around here, at least we think so.

We can get a lot of mileage out of prototype systems, including:

Fieldable Prototypes

Designed for real-world environments and test functionality, durability, and performance under actual operating conditions before full-scale production.

Serial Prototypes

Created in small batches, these are used for developing and evaluating manufacturing methods, assembly lines, as demo units, and for fine-tuning designs.

Pilot Scale Prototypes

These are built closer to the intended production scale and in larger quantities to test the systems, and processes, and ensure quality control works as required.

Transition to Volume Production Prototypes

The final version of a prototype. They are used to confirm the product design, production processes, and materials before volume production begins.
artificial intelligence machine at industrial manufacture factory of lithium battery

Performance & Validation

Our team ensures that the battery pack works as intended via performance and validation testing. Through rigorous validation and analysis for cell selection, battery-scale end-of-line testing, and life testing alongside accurate parameterization for BMS control, you have confidence in production and field use. We are determined to find every problem and challenge before they become costly ones and leverage performance and validation testing and service to achieve just that.

Delivering on Battery Pack Designs

Innovative designs are well and good, but only if they’re practical and they can actually be built in real-life. Our battery-building assets include:

Machine Shop

CNC milling machines and a wide variety of shop tools to create custom designs for battery holders or cooling systems, along with cutting, shaping, and assembling critical components for battery pack structure.

High bay assembly area with hoist

ideal for assembling large or heavy battery packs, such as for electric vehicles or industrial equipment.

3D Printer Lab

Excellent for rapid prototyping and quick design iteration of battery pack components, including custom connectors, internal spacers, and enclosures.

Electrical Engineering Lab

Designing electrical circuitry and testing battery management systems, power distribution systems, and ensuring the electrical integration of the battery pack. Essential for validating key electrical components.

Electrical Equipment Integration Lab

Integrating charging circuits, battery protection circuits, and monitoring systems into the battery pack are all focused alongside testing safety and functionality

Software Integration Lab

Programming and calibration of systems that manage battery charge cycles, communication with other equipment, and temperature control.

From Concept to Production,
Faster, Smoother, With Less Risk.

You have the vision. We have the team and expertise to get it built. Let's collaborate to innovate, problem-solve, and de-risk every step of the way.