Electrification

Building America’s Electrification Capabilities

FROM CONCEPT TO PRODUCTION

Our path to production

Validate electrification and power electronics concepts through feasibility studies, technology roadmapping, and proof-of-concept development to ensure technical, performance, and market viability. 

  • Product and technology roadmapping 
  • Electrification system concept and feasibility 
  • Performance requirements and risk analysis 
  • Battery module and pack prototype development 
  • Trade study analysis execution 
  • Technical and economic feasibility assessment 
  • Requirements validation workshops 
  • Regulatory pathway assessments 

Define system architecture and technical requirements that align electrification performance goals with application needs while optimizing efficiency and integration. 

  • Systems engineering and architecture 
  • Requirements analysis and specification 
  • Power electronics and battery architecture 
  • Battery pack topology and configuration 
  • Charging system and infrastructure architecture 
  • Thermal management and control strategy 
  • Interface control documents 
  • Communication network architecture and diagnostics 

 

Develop complete engineering models, power electronics, and documentation for electrification systems optimized for efficiency, thermal performance, and durability. 

  • Detailed CAD design models 
  • Power electronics and battery management system design documentation 
  • Thermal management and cooling system design 
  • Multi-physics thermal structural electromagnetic simulation 
  • High-voltage and power distribution circuit design 
  • Custom component and subsystem design 
  • Wire harness and high-voltage cable design engineering 
  • Manufacturability for Design (MFD) and assembly reviews

Verify that electrification components and systems meet performance specifications through simulation, prototype testing, and validation under operating conditions. 

  • Prototype builds for functional performance validation 
  • Performance analysis and efficiency optimization 
  • Simulation and thermal validation testing 
  • Battery management and control strategy verification 
  • Sensor, current, and voltage monitoring testing 
  • System load, efficiency, and range testing 
  • High-voltage safety and compliance validation 

Integrate mechanical systems, power electronics, battery systems, and software into complete electrification platforms while validating interfaces and performance. 

  • Custom electrification system assembly and subsystem integration 
  • Power electronics and motor drive systems integration 
  • Battery pack, BMS, and thermal management integration 
  • System control unit and communication system integration 
  • Charging system connectivity and smart grid enablement 
  • Diagnostic, monitoring, and fault management system integration 
  • Software calibration, parameter tuning, and commissioning 
  • Full system functional and performance acceptance testing 

Validate complete electrification systems to meet customer requirements, performance targets, and safety standards through comprehensive testing and validation. 

  • Factory acceptance testing (FAT) 
  • Site acceptance testing and commissioning 
  • Performance validation under operational conditions 
  • Safety EMC and regulatory compliance 
  • User training and technical documentation 
  • System reliability and durability testing 
  • Quality assurance validation 
  • Production readiness and design transfer 

Develop and prove electrification manufacturing processes, assembly procedures, and quality protocols to meet production, performance, and safety standards. 

  • Manufacturing process flow development 
  • Battery assembly and cell integration procedures 
  • Custom equipment, tooling, and fixture fabrication 
  • High voltage assembly and integration procedures 
  • Hi-pot, functional test, and end-of-line test protocol  
  • Critical process parameter definition 
  • Process capability and formal process validation (IQ/OQ/PQ) 
  • Quality control plan development 

Establish manufacturing infrastructure, cleanroom capabilities, and production systems required to scale electrification component and system production. 

  • Custom assembly equipment and tooling 
  • Battery handling and material flow 
  • MES and serial-level traceability development 
  • Electrical testing and end-of-line equipment 
  • Specialized high-voltage equipment and procurement 
  • Operator training and standardized instructions 
  • Quality and safety program implementation 
  • Facility layout and cleanroom planning 

Execute pilot builds of electrification systems and components to validate manufacturing readiness, process capability, and product performance. 

  • Pilot electrification system builds 
  • Power electronics and battery system validation 
  • Custom equipment and tooling testing 
  • Assembly process validation 
  • Quality assurance and performance testing 
  • First-article inspection data 
  • System integration troubleshooting 
  • Manufacturing readiness demonstration 

Scale electrification production volume while maintaining quality standards, safety compliance, and improving efficiency through process optimization. 

  • Incremental production scaling 
  • Workforce training and certification expansion 
  • Process cycle time optimization 
  • Quality yield stabilization and defect reduction 
  • Automated testing and inspection implementation 
  • Lean manufacturing and Six Sigma tools 
  • Performance and traceability monitoring systems 
  • Target production rate achievement 

Manufacture electrification systems and components at full-production volume with consistent quality, safety compliance, and reliable delivery. 

  • Target production volume execution 
  • Standard operating procedures and batch documentation 
  • ISO 9001, IATF 16949, and  compliance maintenance 
  • Customer delivery schedules and JIT requirements 
  • Supply chain coordination and battery cell sourcing 
  • Component and cell lot traceability 
  • Quality control and high-voltage safety monitoring 
  • Preventive maintenance and calibration programs 

Drive systematic improvements in electrification manufacturing through data analytics, yield optimization, and operational excellence initiatives. 

  • Real-time performance and efficiency monitoring 
  • Data-driven process analytics and statistical process control 
  • Predictive maintenance and equipment uptime implementation 
  • Automated process adjustments and closed-loop control 
  • Continuous improvement and root cause analysis feedback loops 
  • Manufacturing system optimization initiatives 
  • Best practice and Lean manufacturing implementation 
  • Customer support, field performance analysis, and design updates 

Our path to production

Validate electrification and power electronics concepts through feasibility studies, technology roadmapping, and proof-of-concept development to ensure technical, performance, and market viability. 

  • Product and technology roadmapping 
  • Electrification system concept and feasibility 
  • Performance requirements and risk analysis 
  • Battery module and pack prototype development 
  • Trade study analysis execution 
  • Technical and economic feasibility assessment 
  • Requirements validation workshops 
  • Regulatory pathway assessments 

Define system architecture and technical requirements that align electrification performance goals with application needs while optimizing efficiency and integration. 

  • Systems engineering and architecture 
  • Requirements analysis and specification 
  • Power electronics and battery architecture 
  • Battery pack topology and configuration 
  • Charging system and infrastructure architecture 
  • Thermal management and control strategy 
  • Interface control documents 
  • Communication network architecture and diagnostics 

Develop complete engineering models, power electronics, and documentation for electrification systems optimized for efficiency, thermal performance, and durability. 

  • Detailed CAD design models 
  • Power electronics and battery management system design documentation 
  • Thermal management and cooling system design 
  • Multi-physics thermal structural electromagnetic simulation 
  • High-voltage and power distribution circuit design 
  • Custom component and subsystem design 
  • Wire harness and high-voltage cable design engineering 
  • Manufacturability for Design (MFD) and assembly reviews

Verify that electrification components and systems meet performance specifications through simulation, prototype testing, and validation under operating conditions. 

  • Prototype builds for functional performance validation 
  • Performance analysis and efficiency optimization 
  • Simulation and thermal validation testing 
  • Battery management and control strategy verification 
  • Sensor, current, and voltage monitoring testing 
  • System load, efficiency, and range testing 
  • High-voltage safety and compliance validation 

Integrate mechanical systems, power electronics, battery systems, and software into complete electrification platforms while validating interfaces and performance. 

  • Custom electrification system assembly and subsystem integration 
  • Power electronics and motor drive systems integration 
  • Battery pack, BMS, and thermal management integration 
  • System control unit and communication system integration 
  • Charging system connectivity and smart grid enablement 
  • Diagnostic, monitoring, and fault management system integration 
  • Software calibration, parameter tuning, and commissioning 
  • Full system functional and performance acceptance testing 

Validate complete electrification systems to meet customer requirements, performance targets, and safety standards through comprehensive testing and validation. 

  • Factory acceptance testing (FAT) 
  • Site acceptance testing and commissioning 
  • Performance validation under operational conditions 
  • Safety EMC and regulatory compliance 
  • User training and technical documentation 
  • System reliability and durability testing 
  • Quality assurance validation 
  • Production readiness and design transfer 

Develop and prove electrification manufacturing processes, assembly procedures, and quality protocols to meet production, performance, and safety standards. 

  • Manufacturing process flow development 
  • Battery assembly and cell integration procedures 
  • Custom equipment, tooling, and fixture fabrication 
  • High voltage assembly and integration procedures 
  • Hi-pot, functional test, and end-of-line test protocol  
  • Critical process parameter definition 
  • Process capability and formal process validation (IQ/OQ/PQ) 
  • Quality control plan development 

Establish manufacturing infrastructure, cleanroom capabilities, and production systems required to scale electrification component and system production. 

  • Custom assembly equipment and tooling 
  • Battery handling and material flow 
  • MES and serial-level traceability development 
  • Electrical testing and end-of-line equipment 
  • Specialized high-voltage equipment and procurement 
  • Operator training and standardized instructions 
  • Quality and safety program implementation 
  • Facility layout and cleanroom planning 

Execute pilot builds of electrification systems and components to validate manufacturing readiness, process capability, and product performance. 

  • Pilot electrification system builds 
  • Power electronics and battery system validation 
  • Custom equipment and tooling testing 
  • Assembly process validation 
  • Quality assurance and performance testing 
  • First-article inspection data 
  • System integration troubleshooting 
  • Manufacturing readiness demonstration 

Scale electrification production volume while maintaining quality standards, safety compliance, and improving efficiency through process optimization. 

  • Incremental production scaling 
  • Workforce training and certification expansion 
  • Process cycle time optimization 
  • Quality yield stabilization and defect reduction 
  • Automated testing and inspection implementation 
  • Lean manufacturing and Six Sigma tools 
  • Performance and traceability monitoring systems 
  • Target production rate achievement 

Manufacture electrification systems and components at full-production volume with consistent quality, safety compliance, and reliable delivery. 

  • Target production volume execution 
  • Standard operating procedures and batch documentation 
  • ISO 9001, IATF 16949, and  compliance maintenance 
  • Customer delivery schedules and JIT requirements 
  • Supply chain coordination and battery cell sourcing 
  • Component and cell lot traceability 
  • Quality control and high-voltage safety monitoring 
  • Preventive maintenance and calibration programs 

Drive systematic improvements in electrification manufacturing through data analytics, yield optimization, and operational excellence initiatives. 

  • Real-time performance and efficiency monitoring 
  • Data-driven process analytics and statistical process control 
  • Predictive maintenance and equipment uptime implementation 
  • Automated process adjustments and closed-loop control 
  • Continuous improvement and root cause analysis feedback loops 
  • Manufacturing system optimization initiatives 
  • Best practice and Lean manufacturing implementation 
  • Customer support, field performance analysis, and design updates 

Featured Projects

SELECT Capabilities

BATTERY PACK DESIGN & DEVELOPMENT

BATTERY PACK DESIGN & DEVELOPMENT

Custom battery pack engineering from cell selection through production-ready design, integrating mechanical packaging, thermal management, high-voltage architecture, and safety systems. From energy density optimization to crash protection and BMS integration, we deliver complete battery solutions for electric vehicles, aerospace platforms, industrial equipment, and stationary energy storage applications.

BATTERY MANAGEMENT SYSTEMS (BMS)

BATTERY MANAGEMENT SYSTEMS (BMS)

Advanced battery management system design and integration featuring real-time monitoring, cell balancing, and protection circuitry to maximize battery lifespan, ensure operational safety, and optimize performance across demanding electrification applications.

THERMAL MANAGEMENT SOLUTIONS

THERMAL MANAGEMENT SOLUTIONS

Advanced thermal management system design for batteries and power electronics featuring liquid cooling, forced air systems, heat exchanger integration, and CFD analysis. From thermal modeling through production implementation, we optimize heat dissipation to maximize performance, extend component life, and ensure safe operation across demanding electrification duty cycles.

BATTERY MANUFACTURING SCALE-UP & AUTOMATION

BATTERY MANUFACTURING SCALE-UP & AUTOMATION

Turnkey battery manufacturing facilities from pilot line to high-volume production, integrating cell-to-pack assembly automation, high-voltage testing infrastructure, cleanroom environments, and digital traceability systems. We build the production capability to scale from hundreds to hundreds of thousands of battery packs annually with ISO 9001/IATF 16949 compliance.

1k+

Circuit Boards Designed

175k

Square Feet of Battery Production Space


15

MWh/yr Prototyping Capacity

Quality & Compliance Certifications

  • AS9100
  • ISO 9001
  • GCCH
  • NIST 800-171 Compliant
  • ITAR Compliant
  • DFARS Compliant
  • CMMC Level 2

Contact us

Tell Us What You’re Building

Power the future with precision engineering solutions built to the highest electrification standards. Partner with us to accelerate innovation while ensuring reliability, efficiency, and compliance.