From prototype to serial production: Flash Battery’s Custom Lithium Battery Development Process

Listening is the First Step: Together with you, we analyse your electric vehicle’s consumption, work cycles and environmental conditions

At Flash Battery, we start by talking things through. We meet with you during a preliminary session to analyse the specific characteristics of the application and its operating conditions. This includes examining dimensions, consumption, operating cycles, downtime available for fast charging and the environmental conditions where the vehicle will operate.

But there’s more! The conditions of the electricity infrastructure and accessibility to the national grid are also crucial to handle the project properly.

Custom Guidance for Turnkey Electrification

Flash Battery has the right electrification solution for any need, whether you’re a large OEM with a well-structured R&D department or a small or medium-sized enterprise that outsources competencies.

With well-established partnerships with seasoned Powertrain System Integrators focused on energy transition, operating in key countries across Europe, such as Atech GmbH in Germany and Q-Tronic in the Netherlands, we deliver complete and tailored electrification solutions. These solutions include not only the battery but also inverters, motors and all components integral to an electric vehicle project.

The goal is always to supply efficient and complete powertrain solutions.

Electrification: Sizing and Design

After establishing a technical panel with all relevant stakeholders and defining the specific requirements of the machine or vehicle, we proceed to the actual battery sizing. This involves determining the appropriate capacity and technical specifications.

With your formal commitment, our Sales Engineer takes charge, ensuring the excellence of the design and overseeing its development through the production, testing and commissioning phases.

This marks the beginning of a validated custom lithium battery development process consisting of 8 simple steps, designed to help you achieve the perfect lithium battery for your application.

The first step, handled by our customisation department, involves drafting the project technical folder, which includes the mechanical configuration of the battery and choosing the electrical components.
You will then receive a technical dossier, complete with 2D and 3D drawings as well as circuit diagrams. Once approved, this dossier gives the green light to the prototype production process and initiates the supply chain for procuring customised components. In no time, your custom battery pack will be ready for testing.

Battery testing and field trials

This is the final test bench, simulating how the battery operates to ensure all parameters are met and that the battery interfaces correctly with the vehicle and charger.

However, the process does not end here! A crucial phase starts when the battery is shipped, i.e. physical installation. We assist you from the initial installation, following the tests and analysing field operations to ensure the battery also suitably meets the most challenging scenarios, so it is all ready for serial production.

Continuous training

From prototype to serial production, Flash Battery provides added value by being consistently by your side so that the batteries are flawlessly integrated, optimising performance and autonomy and minimising maintenance costs for the entire machine or vehicle.

This includes delivering technical training courses for you and your entire sales network, support network and international dealers. These courses offer the necessary skills to help you strategically market the advantages of electrifying with Flash Battery lithium batteries, addressing both sales and post-sales requirements.