As you might be aware, AceOn offers a fully customised battery pack design service for a broad range of clients, operating within a range of sectors at home and abroad.
All of our battery packs are manufactured at our purpose-built, state-of-the-art facility in Telford, England, and we’re very proud of the fact that we’re pioneering the best of British industry.
Our talented and dedicated team of battery technicians are only too happy to take on bespoke custom orders that meet our clients’ exacting specifications, and truly, no project is too large or too small.
From one-off custom orders to regular fulfilments, our team is ready and able to manufacture and supply your company’s every battery need.
But how does battery pack manufacturing actually work? And what makes AceOn stand out as industry leaders?
Let’s take a look now.
UK manufacturing at our plant in Telford.
In the present day, it’s unfortunate that many companies within the UK’s previously thriving manufacturing industry are outsourcing their production to cheaper international markets.
At AceOn, we pride ourselves on the fact that all of our production is carried out in the UK, and we provide training and apprenticeship opportunities to young people in and around Telford to get involved with pioneering energy related products.
Within our Telford plant, we use a variety of specialist equipment to ensure both humidity and temperature control, which provides the perfect environment in which to produce custom battery packs.
Furthermore, our technicians utilise ESD protection and specialised fire control equipment to conduct their work. Our purpose-built warehouse is the perfect setting for our battery pack manufacturing service.
IPC certified soldering and spot-welding process.
One of the most critical components of battery pack manufacturing is soldering. All of our technicians and operators are IPC trained and certified.
The IPC standard for soldering ensures materials, methods, and verification criteria are met across our plant. We take regulation and compliance extremely seriously and regularly check our plant for any potential production risks.
We’re also proud to use the latest spot-welding equipment. In simple terms, this allows us to control and produce the most reliable welds, ensuring your packs are manufactured to the highest possible standard.
Spot-welding is extremely useful when we’re undertaking highly complex custom-builds for many of our commercial clients, as we’re often tasked with delivering on exact criteria.
State-of-the-art heat shrinking oven and soldering station.
Thanks to our state-of-the-art heat shrinking oven, we’re able to shrink tubing in a fraction of the time it would take to use a heat gun for the same purpose.
This is because it reaches the optimum temperature for shrinking in a short space of time, allowing us to work on several component parts at once.
This is excellent news for our clients. Because it is less labour intensive and time-consuming than other methods, our use of the heat shrinking oven enables us to keep our overall production costs down, which is reflected in our competitive pricing model for custom battery packs.
In addition to the oven, our ESD protected soldering stations allow us to work on multiple projects at once, ensuring our orders are fulfilled and shipped in time.
Our plant is designed in such a way that supports multiple assemblies simultaneously, and our experienced technicians ensure the job is done to the highest possible standard.
Wire cutting and stripping, and ultrasonic welding equipment.
To further optimise our production rate and capabilities, we have a digital cutting machine that enables us to program the perfect setting to produce accurate wire lengths included in our packs.
Again, because many of our clients require markedly different wire lengths within their packs, we’ve invested in the necessary equipment to make this possible.
When it comes time to wrap our custom battery packs, we make the use of the latest ultrasonic welding equipment to make sure the pack is tightly configured and perfectly safe when delivered to your site.
After all, your custom battery pack needs to be durable and solid, so it can serve its desired purpose after it leaves our plant.
Pull test equipment.
One of the most important parts of the battery pack manufacturing process is the pull test. Before any pack leaves our plant, we perform a pull test to check the strengths of the tab welds.
This will give us an idea of how the cells have been manufactured, and the test ensures we only send out packs that are built to last and will remain connected while in use.
Final assembly and custom testing.
Once all component parts are affixed, the pack is ready to be assembled. Our technicians bring together all of the individual elements that have been manufactured before sending the pack for testing.
Custom packs contain various components, including circuit boards, thermistors, and membrane switches. It requires specialist knowledge to ensure the parts are affixed appropriately, something our team has many years of experience in.
After the pack has been fully assembled, we send it for testing. We test at both the prototype and production level, as we’re conscious of supplying our clients with only perfect batteries for their required application.
Work with AceOn.
As you can see, we’ve gone to great lengths to ensure we’re at the forefront of battery pack manufacturing. Our technicians and associated production staff are highly trained and technical and are capable of producing packs for a vast array of clients.
So, if you’re looking for the perfect battery pack solution for your professional or commercial needs, be sure to give us a call today on 01952 293 388 and our friendly and dedicated customer support team will be delighted to talk you through the process further.
