PROJECT REPORT CS-03 / DEFENCE

Replacing an obsolete military lithium cell

Client
Confidential
Sector
Defence, legacy equipment
Route
Legacy replacement
Original
Kokam NCM 3.7V 2Ah pouch cell, discontinued
Replacement
Custom 3.2Ah pouch cell, same dimensions
Documents
MSDS, CE and UN38.3 test reports
Delivery
2 months
Custom lithium pouch cell made to replace a discontinued military cell
Fig. 1 / Replacement pouch cell

Brief

Legacy military equipment depended on a Kokam NCM 3.7V 2Ah pouch cell that had been out of production for years. Nothing off the shelf matched it, and the replacement had to fit the existing housing exactly.

Requirements

  1. Identical physical dimensions to the original cell.
  2. Electrically compatible with the equipment and its strip BMS.
  3. Full safety and transport documentation.

Engineering response

We sourced the original manufacturing specifications and strip BMS parameters, then produced a small batch of custom 3.2Ah cells to the exact dimensions of the original: 60 per cent more capacity in the same space.

We also added charge and discharge over-current protection, which the original never had, bringing the safety profile up to current standards.

Result

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

Other project reports

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