Trusted Engineering
Battery Engineering
Contract R&D, custom cell and pack development, process development and QA standards — run by designers with 15+ years across multiple chemistries and BMS architectures. This is where the engineering in “engineering-led supplier” comes from.
2.5V – 600V
mWh – kWh
mA – thousands of amps
Services
What the lab does
We match the part to the shop that runs that process every day — not to whichever supplier happens to be free.
2.5V – 600V
Design voltage range
Single cell through high-voltage series strings
mWh – kWh
Energy range
Coin-cell scale through industrial pack scale
15+ yrs
Designer experience
Multiple chemistries and BMS architectures
Facilities
Lab and equipment
Owned equipment, on site in Texas — not a broker's borrowed capability.
| Category | Equipment |
|---|---|
| Cell & pack assembly | Battery assembly stations, heat sealing, ultrasonic welding |
| Joining | Resistance spot welding, soldering stations |
| Test & cycling | Arbin battery testers, environmental chambers |
| Materials processing | Ball mills, drying ovens, vacuum ovens |
| Electrode processing | Pilot coating line |
Applications
| Sector | Typical program |
|---|---|
| Industrial OEM equipment | Packs for mobile and fixed equipment, integrated with the machine's electrical system |
| Downhole & oilfield | High-temperature, high-shock packs for measurement and tooling |
| Defense & government | SBIR/BAA development programs and qualification support |
| Horizontal Directional Drilling | Packs for locating and steering tools, rated for downhole shock and continuous bore-run duty |
Questions we get asked
Battery engineering — common questions
Answers for engineering teams scoping a cell, pack or test program.
What battery engineering services does BCI provide?
Contract R&D including cell building and materials benchmarking, custom cell and pack development and prototyping, assembly process development, test procedure and SOP authoring, and QA standard development.
Can you design a custom battery pack for industrial equipment?
Yes. We develop custom cell and pack designs — electrical, mechanical and thermal, with the BMS architecture selected for the application — and build and test prototypes in our own lab before production.
Do you work on SBIR or BAA programs?
Yes. We participate in SBIR and BAA programs as prime or subcontractor, including technical proposal content and statements of work.
Can you support high-temperature downhole applications?
Yes. Downhole and oilfield packs are a long-standing application, and qualification testing for temperature and shock is run in our lab before field release.
What voltage and energy range do you design to?
Designs run from 2.5V to 600V, from milliwatt-hours to kilowatt-hours, and from milliamps to thousands of amps of current.
What test equipment does the lab have?
Battery assembly stations, resistance spot welding, soldering, ultrasonic welding and heat sealing, Arbin battery testers, environmental chambers, ball mills, drying and vacuum ovens, and a pilot coating line.
Which battery chemistries do you work with?
Our designers have 15+ years of experience across multiple chemistries and BMS architectures; chemistry is selected against the application’s duty cycle, temperature range and safety requirements rather than defaulted.
Do you offer battery consulting as well as engineering?
Yes — technology assessment, market diligence, commercialisation strategy, patent support, and fractional CTO/COO engagements.
Discuss a battery development program.
Cell and pack development, contract R&D, test procedures and SBIR/BAA partnering.