At Re:Build Battery Solutions, we are committed to delivering high-quality, U.S.-manufactured battery systems that meet the rigorous demands of aerospace, defense, automotive, and energy storage industries.
Our state-of-the-art facility in New Kensington, PA is designed to adapt as your needs grow. With 175,000 square feet of production space (expandable to 750,000), advanced automation, and rigorous quality control, we support everything from low-volume, high-complexity builds to cost-sensitive, high-volume manufacturing, ensuring customers receive consistent quality at any scale.
By manufacturing domestically, we eliminate reliance on overseas suppliers, ensuring faster lead times, supply chain stability, and regulatory compliance.
Our streamlined process accelerates the transition from design to full-scale production, reducing development cycles and getting products to market faster.
ITAR-compliant and AS9100-certified systems meet mission-critical requirements.
At Re:Build Battery Solutions, our battery pack production process is strengthened by strategic partnerships with top-tier battery cell manufacturers, ensuring our customers receive validated, high-quality cells that meet strict performance, reliability, and safety standards. Our domestic and international supplier network gives customers unmatched flexibility in cell chemistries, form factors, and energy densities, allowing us to deliver optimized solutions for diverse applications.
We source only validated, high-quality cells, eliminating the risk of counterfeit or substandard materials.
Our network spans leading domestic and global cell manufacturers, providing access to a broad range of chemistries and configurations.
Our team optimizes battery pack design by carefully integrating the right cell technology for each application, ensuring maximum efficiency, safety, and performance.
We leverage proprietary performance data on cells and modules, giving us a unique advantage in selecting the best solutions for each customer’s needs.
Our close industry relationships position us to deliver cutting-edge battery solutions that align with emerging technology trends and customer requirements.
Utilization studies to assess current capabilities, support production planning, and define multi-phase capital investment strategies.
Re:Build Battery Solutions’ New Kensington facility sets the standard for advanced battery manufacturing. Purpose-built for flexibility, efficiency, and scalability, our production infrastructure is designed to meet the evolving needs of battery manufacturers.
Advanced Equipment – Our facility features laser welding, wire bonding, and high-capacity automated assembly lines, enabling precision production for both low-volume, high-complexity programs and high-volume, cost-sensitive applications.
Certifications & Compliance – We adhere to the highest industry standards, including AS9100 certification and ITAR compliance, making us a preferred partner for regulated industries such as aerospace and defense.
Quality Control & Full Traceability – Our data-driven quality control systems, using multimodal testing with electrical testers, infrared cameras, and physical inspections, provide a comprehensive digital thread for every battery pack, ensuring end-to-end traceability.
15MW of Available Power – Supports high-throughput battery pack production, ensuring uninterrupted, large-scale manufacturing.
Heavy-Duty Operations – A 65-ton crane allows for handling oversized battery packs and modules, ensuring precision and safety in production.
Streamlined Logistics – On-site rail access integrates seamlessly into our supply chain, allowing for efficient transport of raw materials and finished battery systems, reducing costs and transit times.
Scalable Production Space – 175,000 sq. ft. flexible facility, expandable to 750,000 sq. ft., accommodating both low-volume prototyping and high-volume manufacturing.
A leading electric vehicle manufacturer required both standard and extended-range battery packs tailored to the unique form factor, performance, and range requirements of its EV platform. Re:Build led the complete development effort, designing the mechanical, electrical, and software architecture.
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.
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.
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.
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.
Customers gain confidence knowing their packs are built by a team with decades of experience serving aerospace, defense, automotive, and energy storage markets. Our engineering-driven approach and advanced manufacturing capabilities ensure safe, high-performance systems that meet the most demanding standards.
Whether you need prototypes, pilot runs, or high-volume production, our solutions scale with your growth. Customers benefit from flexibility, efficiency, and consistency supported by automation, lean production, and adaptable facilities.
With domestic, ITAR-compliant and AS9100-certified facilities, customers reduce supply chain risks and accelerate delivery. This means faster lead times, assured compliance, and mission-critical reliability for the applications that matter most.
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