Battery Pack Assembly
Count on the battery experts to assemble your packs
Packet Digital has pushed the boundaries of what battery technology can be, and we can put that same commitment to innovation and quality towards your products. When you partner with us for battery pack assembly, you benefit from deep industry knowledge, proven quality control and experience with battery and smart battery development that is virtually unmatched.
Choosing Packet Digital for your battery pack assembly ensures you’re receiving a high-performance battery that is built by an experienced team, meticulously tested and third-party certified. We are a true one-stop-shop as prior to assembly, our team can design and manufacture your product ensuring NDAA compliance and eliminating the risks of overseas supply chain bottlenecks.
We don’t just piece cells together. We utilize automated cylindrical cell sorting, pouch cell matching, automated laser and spot welding, and in-house assembled printed circuit boards to eliminate thermal and electrical imbalances. Whether your drone, UAS, submersible or ground vehicle requires high power density, high energy density, or both, Packet Digital will deliver a reliable, safe, U.S.-built battery with maximum performance.
UN38.3 Certified
NDAA Compliant
Cell Selection & Matching
Testing & Traceability
Battery Pack Assembly
Battery packs are assembled at Packet Digital’s facility in Fargo, N.D. A range of highly sophisticated machinery, including laser and resistance welders, and an automated surface-mount technology (SMT) line, aids in the assembly of mission-ready power systems. Once assembled, finished products undergo thorough testing ranging from thermal and pressure loads to simulate variable mission conditions, as well as electronic testing for any onboard PCBs. This domestic workflow guarantees strict ITAR and NDAA compliance, rigorous bin-and-lot traceability, and a resilient supply chain optimized for drones, UAS, UUV and ground-based platforms for defense and commercial operations.
Packet Digital is CMMC Level 2.0 and ISO 9001:2015 certified in addition to NDAA and ITAR compliant, giving you peace of mind knowing designs are secure and your finished product will undergo the maximum amount of testing and quality control checks before your first shipment. In addition, we are third-party UN38.3 certified so you can rest easy knowing your product will arrive exactly as it should, mission ready.
Identification
Our team will work with you to identify the power needs for your platform as well as the system’s design.
Sourcing
We will determine which components we can manufacture in-house and which need to be sourced independently.
Development
Development begins with designing the battery pack and building prototypes for testing to satisfy certification requirements.
Production
We’ll start with cell matching and then assemble using our state-of-the art manufacturing equipment.
Schedule a meeting with our manufacturing team
How we assemble battery packs
Traceability
Our assembly process starts with material procurement. Every component and every material that goes into our products is tracked and recorded. Traceability doesn’t stop there, however. The assembly process? Tracked. Testing and performance monitoring? Tracked. When Packet Digital assembles your battery pack, you’ll have peace of mind knowing we are monitoring every detail that goes into it’s manufacturing.
Cell Matching
A battery pack is only as strong as its weakest link. Cells with variations in capacity, internal resistance or discharge rates create an imbalance, leading to accelerated degradation, reduced overall pack capacity and premature failure. Before assembly starts, our team matches cells with similar characteristics to ensure optimal power performance.
Laser Welding
Packet Digital has multiple laser welding units giving our battery packs mechanical strength to endure platform vibrations as well as electrical efficiency for components housed inside. Laser welding concentrates on a localized area, forming reliable, industrial strength bond in milliseconds. The welds also reduce waste of bond material further reducing weight of our packs.
PCB Assembly
If you’re looking for a battery pack with onboard electrics such as a battery management system (BMS), Packet Digital has you covered. We can help you design your printed circuit board (PCB) to fit your platform and needs. Then, with our surface mount technology line, we can assemble the printed circuit boards to be the “brain” of your battery.
Resistance Welding
In addition to our laser welders, we also have a resistance welder that creates strong, reliable connections quickly for faster production. The weld is still precise and uses localized heat to protect the cell’s internal chemistry. For cylindrical cells that simply need the durability required to withstand heavy operational vibrations, resistance welding is the way to go.
3D Printing
Not every battery pack design is the same and neither are the platforms our batteries power. Whether you need a custom-designed battery pack enclosure, harness mounts, or any other component, our 3D printing equipment can help you get the most performance out of your uncrewed system. Our team can design based off system requirements or build based off already approved designs.
Final Pack Assembly
This is the final stage of assembly, where all of the pieces to your battery are put together. Wire harnesses are connected, electronics are mounted and the pack is enclosed. Our expert team of battery assemblers will verify the condition and quality of the completed pack before it is sent off for end-of-line testing prior to being shipped.
Testing & Certification
During the design and development stage, our battery packs undergo testing to ensure they can withstand real-world stressors and mitigate risks such as thermal runaway. We accomplish this using our state-of-the-art testing lab which includes thermal and vibration chambers. Additionally, we offer UN 38.3 services if that certification is required.
Warehouse & Shipping
Battery storage requires precise climate control and management to prevent cell degradation. When it comes to shipping, strict adherence to international regulations ensures our packs are packaged to withstand the friction, vibrations and pressure changes of transit. We’re meticulous in assembling and testing your battery packs, but we also understand the importance of warehousing and shipping your finished packs.