Engineering Reliable, High-Performance Energy Solutions​

Battery Management System (BMS) Development ​

Tailored BMS Solutions for Custom Batteries

Re:Build Battery Solutions develops advanced Battery Management Systems (BMS) that optimize safety, performance, and efficiency for lithium-ion battery packs across aerospace, automotive, industrial, and energy storage applications. Our platforms provide intelligent control, extended battery life, and real-time monitoring, ensuring reliable operation even in the most demanding environments.

We offer both Custom BMS Solutions and Ready-to-Deploy Platforms to meet diverse customer needs. With real-time diagnostics, precise voltage and temperature regulation, and advanced fault protection, our systems reduce risk, extend system life, and ensure compliance with global industry standards. Designed for scalability and seamless integration, our BMS solutions deliver reliable, high-performance energy systems tailored to unique operational requirements.

Custom & Ready-to-Deploy BMS Solutions

We understand that every application has unique demands, from the need for high-performance, safety-critical solutions to the requirement for fast deployment and cost efficiency. That’s why we offer both Custom BMS Solutions and Ready-to-Deploy BMS Solutions, ensuring that every customer gets the right balance of flexibility, scalability, and seamless integration with their battery systems. Whether you need a fully tailored BMS designed from the ground up or a pre-engineered solution that can be quickly integrated and customized for your specific needs, we have the expertise to deliver. 

Custom BMS Solutions

For projects requiring tailored engineering, our Custom BMS Solutions are designed from the ground up to meet specific technical and operational requirements.

Seamless Integration – Works effortlessly with your system, maximizing efficiency and avoiding compatibility issues.

Enhanced Performance – Optimized for safety, reliability, and real-time diagnostics.

Scalability – Future-ready designs that support upgrades and modifications as your needs evolve.

Application-Specific Optimization – Designed to match unique power, thermal, and operational requirements, ensuring that dimensions and capacity are precisely tailored to meet customer specifications.

Ready-to-Deploy BMS Solutions

When you need a fast, proven solution, our Ready-to-Deploy BMS provides a pre-engineered, high-quality system that is immediately functional while allowing seamless integration into specific applications.

Rapid Deployment – Get to market faster with pre-tested, field-proven solutions.

Proven Reliability – Built for stable, consistent performance across industries.

Cost-Effective – Reduces upfront engineering costs while maintaining top-tier performance.

Flexibility – Our Ready-to-Deploy BMS solutions offer customization options, ensuring compatibility with unique application requirements.

Reduce NRE Costs & Accelerate Development Timelines

We understand that lowering development costs and accelerating time-to-market are critical to our customers’ success. Our approach to BMS design and development delivers these benefits through modular hardware and software platforms, pre-validated reference designs, and in-house engineering expertise. This combination reduces non-recurring engineering expenses, streamlines customization, and enables customers to move from prototype to production with speed and confidence.

Reduce NRE Costs

Pre-Developed BMS Architectures – Our portfolio of proven reference designs allows customers to start with an existing framework, minimizing custom engineering and lowering upfront development costs.

Configurable Software & Hardware – We leverage modular firmware and hardware platforms to reduce design complexity and speed up the customization process for specific applications.

In-House Engineering Expertise – Our team of power electronics, embedded software, and system integration specialists provides fully controlled, in-house development, eliminating reliance on external resources and reducing project costs.

Custom-Tailored BMS Configurations – We provide uniquely configured BMS solutions that meet each customer’s exact specifications, ensuring seamless integration, optimized performance, and compliance with industry requirements.

Accelerate Development Timelines

Advanced Simulation & Testing: Utilizing cutting-edge modeling, simulation, and validation tools, we rapidly iterate and refine BMS designs to ensure optimal performance and safety.

Seamless System Integration: Our flexible, pre-validated BMS architectures allow for quick adaptation to various battery chemistries and applications, streamlining the design-to-production process.

Collaborative Development Process – We work closely with our customers from day one, ensuring fast decision-making, clear communication, and smooth integration into their battery systems and manufacturing processes.

Fast-Track to Production – Our streamlined design, testing, and validation process ensures that customers can move from prototype to full-scale manufacturing quickly and efficiently, reducing time-to-market.

Key Features

Engineered for Success

At Re:Build Battery Solutions, our Battery Management Systems (BMS) are designed with cutting-edge technology to deliver safety, performance, and reliability. Our expertise spans advanced circuit design, power management, embedded software, and real-time analytics, ensuring seamless integration across aerospace, automotive, industrial, and energy storage applications.

Real-Time Monitoring & Control
  • Continuous tracking of critical parameters including voltage, current, temperature, and State of Charge (SOC).
  • Precision control algorithms to optimize performance and battery longevity.
  • CAN, UART, and I²C communication support for seamless system integration.
Advanced Balancing & Power Management
  • Active and passive balancing to enhance efficiency and extend battery lifespan.
  • Optimized power distribution strategies to maximize energy output.
  • Smart load management for enhanced power efficiency in demanding applications.
Safety & Protection Systems
  • Multi-layered fault protection against overcharging, over-discharging, short circuits, and thermal runaway.
  • Built-in safety mechanisms for compliance with industry standards such as AS9100, ISO, UL, and ITAR.
  • Integrated temperature sensing and dynamic cooling control for enhanced thermal management.
Data Logging & Predictive Analytics
  • High-resolution data capture for performance tracking and long-term reliability assessment.
  • Machine learning and predictive maintenance capabilities to prevent failures before they occur.
  • Real-time diagnostics and remote monitoring for enhanced operational control.
Embedded Software & Firmware Development
  • Customizable firmware solutions for unique system requirements.
  • Advanced fault detection and self-recovery algorithms to ensure uninterrupted operation.
  • Secure, scalable architecture for compatibility with evolving battery technologies.
Industry-Specific Optimization
  • Designed for high-voltage, high-power applications in electric vehicles, UAVs, aerospace, and industrial systems.
  • Configurable BMS architectures to meet customer-specific power, energy density, and environmental requirements.
  • Flexible BMS platforms to support custom and ready-to-deploy solutions across multiple industries.
Flexible System Integration
  • BMS features can be adjusted to align with system requirements, cost targets, and performance needs.
  • Designed to integrate with various battery chemistries, pack configurations, and communication protocols.
  • Functionality can be scaled up or down to balance efficiency, features, and cost.
  • Tailored to meet unique dimensions, capacity, power, thermal, and operational constraints.

See Our Work in Action

Battery Pack Development for Advanced Drone Program

Re:Build Battery Solutions delivered lightweight, high-performance battery packs for a leading defense contractor’s advanced drone program, meeting stringent performance, durability, and U.S. supply chain requirements within a tight six-month timeline.

Scalable Lithium Battery Production & Assembly System​

Re:Build  designed and implemented an automated lithium battery production and assembly system, optimizing materials handling, equipment integration, and process automation to increase productivity, scalability, and global competitiveness for a leading battery manufacturer.

Improve Production Throughput with Industry-4.0 Automation

Re:Build Battery Solutions implemented an Industry 4.0 automated battery cell test station, integrating robotics, visual inspection, and real-time data processing, reducing inspection time by 80%, cutting battery pack assembly time nearly in half, and eliminating manual data entry errors.

Embedded Monitoring Grid Scale Energy Storage

The customer was developing a new grid-scale flow battery and was looking for a low cost, custom, stack health monitor. The available commercial products contained features and functions that were not required as well as other aspects that would have added unnecessary cost into the product.

Your Vision, Our Expertise

Why Choose Re:Build Battery Solutions?

Proven Expertise​

Customers benefit from our decades of experience in battery system architecture, embedded software, and power electronics. This expertise ensures every BMS solution is built for reliability, efficiency, and safety, whether you need a fully custom design or a ready-to-deploy platform. With Re:Build, you gain a partner trusted to deliver systems that power innovation with confidence.

Cutting-Edge Technology

Our customers gain access to the latest advancements in real-time monitoring, predictive analytics, and intelligent power management. These innovations deliver longer battery life, safer operation, and optimized performance across demanding applications. Designed for scalability and flexibility, our BMS solutions are future-ready, adapting as your needs evolve.

Customer-Centric Approach

Every project is built around your requirements. Through close collaboration and clear communication, we ensure seamless integration and faster time-to-market. The result is a tailored solution that provides reliable performance, cost efficiency, and long-term value, whether you’re deploying a proven reference design or building a custom BMS from the ground up.

Speak with an engineer

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