In the race to bring new battery-powered products to market, speed matters. But so does scalability. Many companies move fast to develop a prototype, only to find themselves stuck when it’s time to scale up. Delays, redesigns, and misalignment between engineering and production teams can derail even the most promising product launches.
This is what we call the handoff problem: the breakdown that happens when a project moves from one vendor for prototyping to another for manufacturing. It’s a problem that slows timelines, inflates costs, and puts product quality at risk.
At Re:Build Battery Solutions, we designed our process to avoid the handoff problem entirely. We help our customers move quickly from concept to prototype and then seamlessly into full-scale production, all under one roof.
Most battery pack development projects follow a familiar path: a company partners with a prototyping shop to build a proof of concept, then searches for a different partner who can handle production at scale. But this transition is rarely smooth. Why? Because the prototype is often built without the realities of large-scale production in mind. Materials may be difficult to source in volume, manufacturing processes may not translate well to automation, and quality systems may not be aligned.
In many cases, engineering teams are forced to revisit design decisions they thought were already solved, causing frustration and delaying time to market. This breakdown between prototype and production introduces unnecessary risk, especially for fast-moving startups or OEMs with aggressive launch timelines.
Re:Build Battery Solutions solves the handoff problem by uniting both stages of the product journey. From the start, our engineering, testing, and manufacturing teams collaborate on a development process that is built for scalability.
We support every phase of battery pack development, including:
Because all of these services are handled in-house, we maintain tight feedback loops between design, testing, and manufacturing. This ensures that design decisions are made with manufacturing and reliability in mind from the very beginning.
Consider a company developing a new battery-powered ground robot for industrial inspections. They need a rugged 48V battery pack that meets tight form factor and thermal requirements, with a custom BMS and long cycle life. Re:Build Battery Solutions helps them design and prototype a working unit within weeks. Our engineers validate thermal and structural performance, while our BMS team tailors the firmware to the application.
Once the prototype is approved, we move directly into production without any handoff to a different vendor, without redesigning for scale, and without losing momentum. Because our team has already been involved since day one, the transition is not really a transition at all. It’s a continuation of the same process, optimized for speed and execution.
In today’s competitive environment, time lost in handoffs is opportunity lost in the market. Every delay in transitioning from prototype to production increases the risk of missed launches, rising costs, and lost investor or customer confidence.
By combining rapid prototyping capabilities with full-scale production services, Re:Build Battery Solutions gives companies a faster, more reliable path to commercialization and avoid the typical pitfalls and move forward with confidence.
If you’re developing a battery-powered product and want to avoid the handoff problem, let’s talk. Whether you’re designing a battery system for an electric vehicle, a drone, or a new industrial device, we can help you move from prototype to production with less friction and increased velocity.
Connect with our engineering team to explore how our integrated battery pack development process can accelerate your next launch.
Looking to connect with an experienced team?
Look no further than Re:Build Battery Solutions! We are excited to connect with you.
