Custom Engineering & Bespoke Solutions

Core Engineering Capabilities:

Barbados Export: 40x 120Ah Units

Dangerous Goods Logistics · Caribbean Export

The Challenge: Move around forty 12.8V 120Ah lithium batteries from the UK to Barbados on a tight deadline. The shipment had to be fully compliant with dangerous-goods (DG) rules to avoid being held in customs or damaged in transit.

Our Solution: We handled the battery logistics end-to-end. This included configuring the packing, applying DG-compliant labeling, and preparing the specific documentation the freight forwarder required. This ensured there was one supplier responsible for both the product and the paperwork—preventing the usual "blame game" between vendor and shipper.

Outcome: The full shipment cleared and landed on time, with zero damage and no paperwork issues. Delivered within 2 months of order date.

British Antarctic Survey

Custom BMS · Heater Logic · Air Transport

The Challenge: Build 20Ah and 7Ah batteries for remote mountain survey equipment. The brief was strict:

• Must comply with <100Wh airline hand-luggage rules (for 7Ah units).
• Ultra-low self-discharge rate while active.
• Must charge from a small 20W solar panel in -30°C conditions.
• Requires extra thermal insulation within the casing.

Our Solution: We engineered a custom 7Ah size with a bespoke BMS program. Crucially, we customised the heater logic to draw power only from the charge input (solar), preserving the battery's stored energy. We also added high-density thermal insulation inside the case during assembly.

Outcome: Batteries are currently active in -30°C environments across Europe & Asia, allowing survey equipment to remain active with only 1–2 maintenance visits a year.

Legacy Military Hardware Support

Reverse Engineering · Pouch Cells · Strip BMS

The Challenge: Match a discontinued Kokam NCM 3.7V 2Ah lithium pouch cell for legacy military equipment. The original cell was out of production with no off-the-shelf equivalent available.

Our Solution: We sourced the original manufacturing specifications and "Strip BMS" parameters. Our engineers then produced a small batch of custom 3.2Ah cells (higher capacity) that perfectly matched the physical dimensions.

We upgraded the safety profile by adding Charge and Discharge Over-Current protections, which the original cells lacked, to meet modern safety expectations.

Outcome: A drop-in replacement delivered with full MSDS, CE, and UN38.3 test reports. Delivered within 2 months.

Nuclear Site (Radio Silent)

Strict Compliance · Custom Hardware

The Challenge: Due to strict site rules regarding radio-emitting devices on nuclear power sites, the customer required a 24V 230Ah battery with NO Bluetooth radio. However, the battery still needed internal heaters to allow for winter charging on an unmanned site.

Our Solution: Standard batteries cannot simply have features "turned off" reliably enough for this regulation. We engineered a custom version of our 24V battery with the Bluetooth module physically removed and CAN-bus/Active Balance logic disabled to maximize standby efficiency.

To meet a tight air-freight deadline, we also produced a smaller 24V 105Ah custom shell version to facilitate rapid shipping.

Outcome: Delivered a fully compliant, radio-silent battery via air freight within 4 weeks.

Confidential Marine Redundancy System

Custom Case · Self-Backup Logic · Victron Comms

The Challenge: Develop a 24V battery logic capable of "Self-Backup." If the primary battery bank fails or encounters an error, the secondary bank must auto-detect the failure and activate instantly to maintain critical power.

Our Solution: We created a custom metal-cased battery (to fit specific container constraints) containing dual BMS logic layers. We also supported the customer in building a proprietary protocol table to allow the batteries to communicate detailed data to their specific Victron monitoring setup.

Status: Ongoing. Prototypes delivered and currently undergoing stress-testing.