High-Performance Battery Solutions for Advanced Drone Systems

Battery Pack Development for Advanced Drone Program

Capabilities Demonstrated

  • Battery pack concept and design.
  • Engineering services, including mechanical and electrical design and analysis.
  • Prototyping and performance testing.

The Challenge

The client, a leading defense contractor specializing in aerospace and defense technologies needed a reliable and high-performance battery pack designed specifically for its advanced counter-UAS (unmanned aircraft system) drone program. The battery packs had to meet strict requirements, including optimizing vehicle weight, maximizing flight time, and withstanding the physical demands of launch, flight, and landing. Additionally, the client required components that were sourced from trusted U.S. suppliers to ensure reliability and align with national priorities. Compounding the complexity, the project required adherence to tight program timelines, completing the transition from concept to prototype in just six months to meet mission-critical deadlines.

The Re:Build Battery Solutions team was tasked with:

  • Collaborating closely with the client’s engineering team to ensure alignment with system specifications.
  • Rapidly designing, prototyping, and testing novel battery packs to meet critical mission deadlines.

The team deployed an integrated approach that ensured seamless communication and rapid iterations, while leveraging quick-turn prototyping processes.

Solution

The team developed and implemented the solution in two phases:

  • Design Phase: A lightweight and high-performance battery pack was conceptualized to meet energy density, weight, and loading constraints.
  • Prototyping Phase: Functional prototypes were created and rigorously tested to validate the design under real-world flight conditions.

System Overview

 The advanced drone system included:

  • Battery Configuration: Battery packs optimized for thermal efficiency, weight management, and easy installation.
  • Performance Enhancements: Systems engineered to endure launch and landing stresses.

Benefits

  • Operational Efficiency: Achieved all performance and durability goals.
  • Mission Success: Enabled the client to meet critical deadlines, ensuring the project’s success.
  • Strategic Impact: Strengthened domestic supply chains by leveraging U.S.-based manufacturing.

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Let’s discuss how we can bring innovative solutions to your most challenging projects. Contact Re:Build Battery Solutions to learn more about our expertise in Battery Pack Design and Development for advanced applications.