Solutions Engineering for Mission-Critical Applications

Custom Solutions

Transforming aspirational requirements into sustainable, executional products.

Solutions Engineering

Our engineering teams operate where commodity solutions fail. We design complex battery and power systems for applications where safety, reliability, and performance are non-negotiable.

  • Deep technical integration with your design team
  • Engineered for extreme environments and harsh conditions
  • Strategic lifecycle support from concept through 10-15+ years in the field

  • Cost-down exercises, design optimization, system integration, and supply chain scaling

solutions engineering

Custom Power Starts with Your Application

We believe a successful battery or power system design begins with the operating profile, not a catalog part number.

Ultralife engineers evaluate voltage, current demand, pulse load, runtime, space envelope, operating and storage temperature, safety requirements, shipping classification, certifications, and total lifecycle requirements. For lithium thionyl chloride systems, for example, cell or pack configuration, temperature range, current rate, capacity, available space, safety, UN shipping requirements, quality certifications, cost, and availability are all key selection factors.

From there, the design can be optimized around:

  • Lithium chemistry selection

  • Cell format and configuration

  • Series and parallel pack architecture

  • Welded or soldered interconnects for continuity reliability

  • Protection electronics and safety devices

  • Mechanical packaging, connectors, and sealing

  • Charger, docking, or power supply integration

  • Communications and electronics system compatibility

  • Compliance and transport requirements

Scorpion battery

Our Engineering Process:

Concept ➜ Application
Definition
Chemistry & Architecture
Selection ➜ Quote
Mechanical & Electrical
Design ➜ Development
Prototype &
Verification
Qualification &
Compliance
Regulatory &
Certification Support
Pre-Production
Production
Delivery & Debrief
Lifecycle Support

Trusted by leading enterprises,
governments, and defense agencies

Case Study: Medical Cart Power Systems

Hospital medical cart manufacturer eliminates downtime with our hot-swappable lithium power systems and collaborative engineering approach.

Case Study: Designing Large-Format Custom Battery Packs

When your system demands a battery that doesn’t exist, how do you design for safety, reliability, and certification without sacrificing schedule or innovation?
For OEMs, the answer is a battery partner who can engineer the impossible.

Bridging the Gap: How a Hybrid Cell Architecture Delivers High-Rate Power with Moderate-Rate Ruggedness

Resolving the power vs. ruggedness constraint. How a new hybrid Li/SOCI2 program was initiated in response to a specific OEM requirement.

Ultralife Videos

The Engineering Behind Ultralife’s Power Solutions

Our collective expertise in mission-critical applications can help you design products for the long haul. Listen to Hari Nayer, our VP of Product Innovation, explain how our experience and expertise can benefit what you bring to market

A Customer’s Honest Review

Real feedback from the field! Hear how a customer in the Netherlands became a true believer in Ultralife batteries after seeing them outperform the competition—even after the warranty expired. Thoughtful engineering makes all the difference!

How Ultralife Adapts Processes for Every Customer

Discover how Ultralife balances structure and flexibility in project management! Hari Nayar, VP of Product Innovation, shares how their team adapts processes to meet each customer’s unique needs, while never compromising on quality or safety. Whether you have strict standards or need guidance, Ultralife’s “rigid yet flexible” approach ensures your project is in good hands.

How Ultralife Turns Concepts into Reality

Transform your ideas from a simple sketch into a real, executable goal with Ultralife’s decades of expertise. From concept to engineering and global manufacturing, we’re here to support your product journey every step of the way.

Your Niche Solution Provider for Complex Power Systems

Looking for more than just a battery? Discover how Ultralife transforms simple power into sophisticated solutions for cameras, data centers, drones, and more. If you need a partner who thrives on turning complexity into results, Ultralife is your go-to. Watch Hari Nayar explain why the right solution provider makes all the difference!

Let’s Talk About Your Application

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