Custom Battery Development
We design and manufacture custom battery systems for demanding applications - from lightweight drone packs to ruggedized industrial modules. Every project starts with your requirements and ends with a production-ready solution.
Markets We Serve
FPV Drone Batteries
Purpose-built battery packs for FPV platforms where every gram counts and peak current defines performance. We engineer cells, BMS and enclosures as a single optimized system - not off-the-shelf assemblies.
Discuss FPV
UAV Battery Systems
Mission-critical battery systems for professional UAV platforms. Engineered for reliability over thousands of cycles, integrated BMS with telemetry, and optimized energy density for maximum endurance.
Discuss UAV
UGV Battery Systems
Ruggedized battery modules for ground-based unmanned platforms. Designed for shock, vibration, dust and water ingress - with high peak current capability and intelligent power management via CAN bus.
Discuss UGV
Robotics Battery Systems
Battery systems engineered for the unique demands of autonomous robots - from warehouse AMRs running 24/7 to medical and service platforms where reliability is non-negotiable.
Discuss RoboticsDevelopment Process
Requirements Analysis
Voltage, capacity, discharge rate, dimensions, weight, operating environment, certifications
Concept & Simulation
Cell selection, thermal modeling, mechanical design, BMS architecture
Prototype Manufacturing
Functional prototype with custom enclosure, BMS, connectors and wiring harness
Testing & Validation
Cycle life, thermal performance, vibration, IP rating, safety compliance
Serial Production
Volume manufacturing with quality control, traceability and logistics
Why Custom Battery Development
Off-the-shelf batteries are designed for average use cases. Your application is not average.
Available Configurations
Electrical
- -Cell chemistry (LiFePO4, NMC, LTO)
- -Cell manufacturer selection
- -Voltage (3.2V - 800V)
- -Capacity (1 Ah - 1000 Ah)
- -Continuous current
- -Peak current
Mechanical
- -Custom dimensions
- -Shape optimization
- -Connectors
- -Mounting system
- -Liquid/air cooling
- -Heating system
- -IP54 - IP67 protection
Electronics
- -Smart BMS
- -CAN bus
- -UART
- -RS485 / Modbus
- -Bluetooth
- -Active balancing
Manufacturing
- -Single prototype
- -Pilot batch (10-50 pcs)
- -Serial production (100+ pcs)
- -Annual volume programs
Development Process
Requirements
Technical specification, operating conditions, certifications, timeline, volume
Engineering
Cell selection, pack architecture, BMS design, thermal simulation, mechanical design
Prototype
Functional prototype with production-intent BMS, enclosure and connectors
Testing
Electrical, thermal, vibration, safety testing per application requirements
Optimization
Design refinement based on test results, cost optimization, DFM review
Production
Volume manufacturing with incoming inspection, process control and traceability
Frequently Asked Questions
What is the minimum order quantity?
We start from a single prototype. Pilot batches typically start at 10-50 units. Serial production from 100+ units per year.
What cell chemistries do you work with?
Primarily LiFePO4 (LFP) and NMC. We select the optimal chemistry based on your application requirements - energy density, cycle life, safety, temperature range.
How long does development take?
Typical timeline from requirements to tested prototype is 8-16 weeks depending on complexity. Pilot batch production adds 4-8 weeks.
Do you provide BMS development?
Yes. We develop custom BMS with the communication interfaces, protection features and monitoring capabilities your application requires.
What certifications can you support?
We design for CE, UN38.3, IEC 62619, UL, and application-specific standards. Certification scope is defined during the requirements phase.
Where is manufacturing located?
All engineering and manufacturing is done in our 4,000 m2 facility in Ukraine. We have been operating since 2014.
Why Tornado Power
10+ Years of Battery Engineering
Deep expertise in cell chemistry, pack design, BMS development and thermal management
4,000 m² Manufacturing Facility
In-house prototyping, testing and serial production in Ukraine
Full-Cycle OEM/ODM
From requirements analysis through prototype to certified serial production
LiFePO4 & Li-ion Expertise
Cell-level knowledge for optimal chemistry selection per application