service - pack prototyping & testing
Solid Energies Inc. (SEI) helps battery developers and product teams turn material concepts into testable cells and functional battery packs. Our services connect materials engineering, prototype fabrication, testing, and manufacturing development so you can evaluate performance, resolve design challenges, and prepare for scale-up.
Pack Development
Battery Pack Engineering and Assembly
- Electrical Integration. Develop cell interconnections, bus bars, power and communications harnesses, and BMS integration. Custom BMS development is scoped to the application.
- Mechanical and thermal design. Develop housings, frames, and cell layouts, with passive, air-cooled, or liquid-cooled thermal management as appropriate.
- Architecture evaluation. Access module and cell-to-pack arragnements. Structural battery concepts and load-bearing frames require application-specific mechanical validation.
- Prototype and pilot builds: Assemble modules and complete packs, then refine the design and assembly process for repeatability and manufacturing readiness.
Engineering Design Support
Services include 2D and 3D CAD, feasibility studies, finite element analysis, tolerance analysis, design for manufacturing, and design failure mode and effects analysis. The project scope defines the drawings, prototypes, test reports, or process documenation to be delivered.
Testing and Validation
Build a test plan around the decisions your team needs to make, from material selection and cell benchmarking to pack design verification.
Test Area Purpose
Cycle life and calendar aging Track capacity, energy, resistance, and degradation under defined conditions.
DCIR and HPPC Liquid, gel, semi-solid, all-solid-state systems, subject to material compatibility
Cell assembly Stacking, tab-welding, electrolyte filling, sealing, formation, and degassing
Moisture management Dry-room processing with dew-point requirements defined for the chemistry
Battery Pack Engineering and Assembly
Electrical integration. Develop cell interconnections, busbars, power and communications harnesses, and BMS integration. Custom BMS development is scoped to the application.
Mechanical and thermal design. Develop housings, frames, and cell layots, with passive, air-cooled, or liquid-cooled thermal management as appropriate.
Architecture evaluation. Assess module and cell-to-pack arrangements. Structural battery concepts and load-bearing frames require application-specific mechanical validation.
Prototype and pilot builds. Assemble modules and complete packs, then refine the design and assembly process for repeatability and manufacturing readiness.
Engineering Design Support
Services include 2D and 3D CAD, feasibility studies, finite element analysis, tolerance analysis, design for manufacturing, and desiign failutre mode and effects analysis. The project scope defines the drawings, prototypes, test reports, or process documentation to be delivered.
Testing and Validation
Build a test plan around the decisions your team needs to make, from material selection and cell benchmarking to pack design verification.
Test Area Purpose
Cycle life and calendar aging Track capacity, energy, resistance, and degradation under defined conditions
DCIR and HPPC Evaluate resistance and pulse-power behavior across operating conditions
Rate and temperature mapping Characterize performance across selected charge, discharge, and temperature conditions (-70 deg C to +120 deg C)
Electrochemical Impedance
Spectroscopy Investigate resistance and interfacial changes in materials and cells.
Safety and abuse evaluation Nail penetration, overcharge, external short circuit, thermal-storage tests with suitable samples and facilities.
Cell testing up to 400A on 5V channels is subject to configuration, duty cycle, and sample requirements. Pack testing is scoped separately; temperature conditions must match the sample and equipment limits. Agree to test methods and acceptance criteria before testing. Product certification is a separate scope.
Why Work with SEI
Connected development. Coordinate material, cell, and pack work with one engineering partner.
Application-specific scope. Match the development plan to your electrical, mechanical, thermal, and performance requirements.
A practical path to scale-up. Use prototype results to improve design, process consistency, and pilot-build readiness.
Supply-chain planning. Identify sourcing and traceability requirements early, including project-specific defense procurement requirements where applicable.
Discuss Your Project
Tell us about your application, including target voltage, capacity, power, dimensions, quantity, and timeline. For materials, or testing projects, also share the chemistry, sample format, and evaluation objectives, and we will recommend a scope and next steps.
Accelerate Your Energy Storage Innovations
Expert Team | State-of-the-Art Lab | Tailored Solutions
Contact our Engineering Team to discuss your project specifications
Email: contact@solidenergies.com
