Capabilities

Battery Pack Design and Development

We specialize in engineering advanced battery packs tailored to the unique needs of industries such as aerospace and defense, automotive, transportation, recreational, and industrial applications. Our portfolio of reference designs, built using a combination of internally developed and off-the-shelf modular building blocks, helps reduce battery pack NRE costs and accelerate development timelines. These designs incorporate cutting-edge features, including advanced cooling systems, state-of-the-art battery management systems (BMS), and robust environmental protections to ensure durability under extreme conditions such as shock, vibration, and impact. With deep expertise in engineering and manufacturing, we deliver innovative, high-performance battery solutions that optimize reliability, safety, and efficiency, empowering our clients to succeed in even the most demanding environments.

Engineering Design & Analysis
  • Systems engineering
  • Mechanical product development
  • Electrical design and analysis
  • Structural design and analysis
  • Thermal modeling, design, and analysis
  • Computational fluid dynamics (internal and external flow)
Circuit & Embedded Systems
  • Circuit board design and schematic capture
  • PCB layout
  • Embedded software development
  • RF and wireless
Prototyping & Manufacturing
  • Design for manufacturing and assembly (DFMA)
  • Prototyping and testing

Battery Management Systems Design, and Development​

Re:Build’s battery management systems (BMS) are engineered to deliver strategic advantages in time-to-market, information security, and performance for battery-powered systems.​ We design and develop BMS hardware and software for a variety of technologies, including Li-ion batteries, PEM and solid-oxide fuel cells, and flow batteries. Our BMS solutions are deployed across a wide range of mobile and stationary applications, from commercial and industrial storage to passenger vehicles, motorcycles, UAVs, and more.​ With a flexible approach to development, we offer customers the choice between custom-designed systems or off-the-shelf solutions, tailored to meet specific requirements. Unlike conventional BMS products that limit configurability and data control, our advanced systems empower you with complete control over customization, data integrity, and operational performance—giving you the tools to optimize your battery systems and drive success.

  • Custom BMS Solutions: Tailored to meet the unique specifications of your application, ensuring optimal performance and seamless integration.
  • Off-the-Shelf BMS Solutions: Ready-to-deploy systems designed for reliability, efficiency, and ease of implementation across various applications.

Battery Pack Production

Re:Build Battery Solutions takes pride in delivering high-quality, made-in-the-U.S.A. battery systems. Our state-of-the-art production facility near Pittsburgh, Pennsylvania, utilizes advanced manufacturing processes for module and pack development. Spanning 175,000 square feet—with plans to expand to 750,000 square feet—our facility is designed to scale with your needs, ensuring flexibility and growth. 

We employ data-driven process monitoring to provide real-time quality control throughout every stage of production. This approach supports seamless progression from product introduction to high-volume manufacturing, ensuring the quality, yield, and efficiency required to stay competitive in today’s demanding market. Leveraging multimodal data from electrical testers, infrared cameras, and physical inspection stations, we build a robust digital thread for every battery cell, module, and pack, enabling full traceability and process optimization.

Our commitment to excellence is reinforced by in-house quality engineering, lean manufacturing principles, and an integrated supply chain. These capabilities allow us to deliver exceptional products at competitive prices, meeting the highest industry standards. 

Facility Features:

  • Laser welding and wire bonding equipment
  • 65-ton crane for heavy-duty operations
  • Rail access for streamlined logistics
  • Up to 15MW of available power to support high-capacity manufacturing
  • Low-volume, high complexity programs
  • High-volume, cost-sensitive programs
  • AS9100 certified
  • ITAR compliant
Battery Pack Production - New Kensington
Battery Pack Production - New Kensington
Battery Pack Production - New Kensington

Battery Assembly Line Design, Build, and Scaling​

We are experts in process development, dedicated to helping you scale your production operations efficiently and effectively. Beyond our in-house production capabilities, we specialize in the design, construction, installation, and commissioning of battery assembly lines in your facility, tailored to meet your specific requirements.

For added flexibility, we offer the option to operate your battery assembly line directly at your facility, ensuring seamless integration and optimal performance. Whether you need support scaling an existing operation or building a new one, our expertise ensures streamlined processes, increased efficiency, and reliable outcomes.

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