Turnkey Pack Assembly — From Concept to Container
For OEM/ODM clients who need a complete battery pack without managing the supply chain, our turnkey assembly service covers every step: design for manufacturing, BMS integration, enclosure fabrication, environmental qualification, and shipping.
Service Scope
- Requirements Workshop — voltage, capacity, mechanical envelope, environmental, certification targets, budget range
- Pack Architecture Design — series/parallel configuration, cell selection, BMS specification, thermal management strategy
- Mechanical Engineering — sheet metal design (SolidWorks/STEP), laser cutting, welding, IP-rated enclosures
- BMS Integration — custom BMS boards or commercial BMS (Daly, JBD, JK, ANT) configured for your application
- Wire Harness Assembly — high-current cables, signal wiring, sealed connectors, color-coded per your spec
- Environmental Qualification — temperature cycling, vibration, shock, salt spray (optional), IP rating verification
- Safety Testing — overcharge, over-discharge, short-circuit, thermal abuse, nail penetration (for certification)
- Logistics — UN3480/UN3481 compliance, dangerous goods declaration, sea or air freight
Typical Applications
Electric Vehicles
Electric motorcycles, e-bikes, e-scooters, neighborhood EVs, golf carts, low-speed vehicles, electric boats, light commercial trucks.
Energy Storage Systems
Residential storage (5kWh-50kWh), commercial storage (100kWh-1MWh), industrial storage, microgrid, off-grid solar.
Specialty Vehicles & Industrial
Forklifts, AGVs (automated guided vehicles), mining vehicles, port equipment, airport ground support, marine propulsion, RV house banks.
Production Capacity
- Cell matching & welding: 5,000 packs/month
- BMS programming & testing: 10,000 units/month
- Enclosure fabrication (sheet metal): 2,000 units/month
- Full assembly line: 3,000 packs/month across 4 SKUs
Quality Assurance
- ISO 9001:2015 quality management
- IATF 16949 for automotive projects (planned Q4 2026)
- 100% end-of-line testing: capacity, internal resistance, BMS function, insulation resistance, Hi-Pot test
- Sample retention program (5+ years for automotive)
- Batch traceability via QR code scan back to cell lot numbers
Project Workflow
Standard project timeline:
- Week 1-2: requirements and design
- Week 3-4: prototype fabrication
- Week 5-6: customer testing and iteration
- Week 7-8: design freeze and pre-production run (5-20 units)
- Week 9+: mass production with rolling delivery
Engagement Models
- NRE (Non-Recurring Engineering) — one-time tooling/setup fee, customer owns design
- Unit pricing — per-pack price including materials and labor
- Hybrid — NRE for first article, then per-unit pricing
Logistics & Compliance
We handle dangerous goods classification (UN3480 cells, UN3481 packs in equipment), HS code advisory (8507.60 for cells, 8504.40 for assembled packs), IMDG-compliant packaging, and customs documentation for global delivery.