battery design

From design to deployment, ION will help you build a world-class battery

ION Energy’s battery designs and the ecosystem focuses on a customizable and modular approach. From conceptualization to making it ready to manufacture, we provide an end-to-end solution for designing use-specific Lithium-ion battery packs and BMSs.

ION leverages its deep domain expertise in the energy storage space to deliver the perfect design for your application.


After understanding the application and requirements of the Li-ion battery, ION will carefully select the right cell chemistry and provide the most effective concepts, aesthetics & materials.

ION will work with you to select the type of cells & form factor based on the end goal of your application and help you achieve the highest lithium-ion battery efficiency.

battery designing

Engineering Design

Cell Selection: Once the ideal Li-ion cell is selected, ION Energy evaluates the combination of these cells to correctly fit the application and deliver higher uptime. Choosing the right supplier of cells for your application is also an integral part of the process and ION is here to guide you every step of the way.

Thermal Management: One of the most important parameters for a Li-ion battery is Temperature. To have an efficient, high performing and long-lasting battery, thermal management plays a key role in distinguishing your product. ION will work with you to design a battery that works perfectly with the cooling system. For standalone designs, we ensure that we design for custom thermal management solutions to always keep your battery in what we like to call the Goldilocks Zone.

Electro-mechanical Assembly: Design for Manufacturability (or DFM) is an essential component of any custom Li-ion battery pack. We assist companies in the design and execution of complete electro-mechanical assembly for their battery packs.

Structural Design: The electro-mechanical assembly ties in with the battery structure directly. We ensure that we design and develop the outer body/casing structure to directly fit into your application that works more like a plug and play system for you. 

Design Analysis: We are obsessed with customer success and take our designs seriously. We ensure they meet the right certifications and standards demanded by the industry today. We run the designs through various simulations, both, at a part level and at an assembly level to ensure that we have designed something that meets the most stringent standards.

Testing & Validation

Prototyping: After the initial designs are finalized, a few prototypes of the battery pack are iteratively tested in diverse operating environments. The feedback generated by the iterations results in a more robust Li-ion battery, which is ready to be deployed in different geographies and climate conditions.

QA & Testing: At ION Energy, we believe in putting out high-quality products. ION’s rigorous testing procedures ensure the battery fits the user’s requirements of high efficiency and higher up-time.

Certification: All the Li-ion battery packs and BMS that are designed at ION Energy follow a strict procedure to meet the requirements for certification – be it general certifications such as UN 38.3, IEC 62133, or application-specific certifications like ISO 12405, ISO 26262, IEC 62660, our team is well equipped to get it done. We also help companies pass product certifications such as the ARAI 048 & AIS 004.

Ready to Manufacture and Launch

We understand that building Li-ion battery prototypes is not enough. That’s why we provide an end-to-end solution assisting you with short-run production, supply chain, and a consistent assembly line set-up. Our success lies in enabling companies that are headstrong to make a difference for the sustainability of the planet.

Ready to design a world-class battery?

Get in touch with our sales team