Custom Engineering & Bespoke Solutions

Barbados Export: 40x 120Ah Units

Dangerous Goods Logistics · Caribbean Export

The challenge: Move forty 12.8V 120Ah lithium batteries from the UK to Barbados on a tight deadline, fully compliant with dangerous-goods rules. Lithium is treated like a hazardous material in shipping; one wrong label and the whole pallet sits in customs.

What we did: Handled the full battery side end-to-end. Configured the packing, applied DG-compliant labelling, and prepared the freight forwarder's specific paperwork. One supplier owned both the product and the documentation, which kills the usual blame game between the battery vendor and the shipping company.

British Antarctic Survey

Custom BMS · Heater Logic · Air Transport

The challenge: 20Ah and 7Ah batteries for remote mountain survey kit. The brief was strict:

• 7Ah units had to come in under the <100Wh airline hand-luggage rule.
• Ultra-low self-discharge so the kit could sit unattended for months.
• Charge from a 20W solar panel in -30°C.
• Extra thermal insulation built into the casing.

What we did: Built a custom 7Ah size with a bespoke BMS program. The clever bit was the heater logic - we set it to draw only from the solar input, never from the battery's own stored energy. That way the heater can keep the cells warm enough to charge without quietly flattening the pack overnight. We also packed high-density thermal insulation inside the case during assembly.

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 hadn't been made in years and there was no off-the-shelf equivalent that fit the existing housing.

What we did: Sourced the original manufacturing specs and Strip BMS parameters, then produced a small batch of custom 3.2Ah cells - a capacity bump on the original - that matched the physical dimensions exactly. While we were at it we added charge and discharge over-current protection, which the original cells didn't have, to bring the safety profile up to modern standards.

Nuclear Site (Radio Silent)

Strict Compliance · Custom Hardware

The challenge: Strict site rules on radio-emitting devices meant the customer needed a 24V 230Ah battery with no Bluetooth radio whatsoever. But the battery still had to keep its internal heaters for unmanned winter charging.

What we did: Standard batteries can't just have features "switched off" reliably enough to satisfy a regulator. We engineered a custom 24V build with the Bluetooth module physically removed and the active-balance comms disabled to maximise standby efficiency. To hit a tight air-freight deadline we also produced a smaller 24V 105Ah custom-shell version for rapid shipping.

Confidential Marine Redundancy System

Custom Case · Self-Backup Logic · Victron Comms

The challenge: A 24V battery with "self-backup" logic. If the primary bank trips or throws an error, the secondary bank has to detect it and pick up the critical load instantly - no human in the loop.

What we did: Built a custom metal-cased battery sized to fit a specific container, with dual BMS logic layers running in parallel. We also worked with the customer to author a proprietary protocol table so the batteries could feed detailed real-time data into their bespoke Victron monitoring stack.