Guiding Every Project from Idea to Production
New Product Development Process
Solutions Engineering for Mission-Critical Applications
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.
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
Concept → Application Definition
Every successful battery and power solution begins with a thorough understanding of the application. During this stage, Ultralife works closely with customers to define performance requirements, operating environments, power profiles, physical constraints, safety considerations, and business objectives. The result is a clearly documented application definition that establishes the foundation for all subsequent development activities.
Chemistry & Architecture Selection → Quote
Once application requirements are defined, our engineering team evaluates the optimal battery chemistry, cell format, and system architecture to meet performance, cost, safety, and lifecycle objectives. Factors such as energy density, power delivery, operating temperature, rechargeability, service life, and regulatory requirements are carefully assessed to identify the most effective solution.
Mechanical & Electrical Design → Development
With the system architecture established, Ultralife’s engineers develop the detailed mechanical and electrical design. This phase includes battery pack design, electronics development, protection circuitry, battery management systems, enclosure design, interconnects, and thermal management. Designs are optimized for performance, manufacturability, reliability, and long-term serviceability.
Prototype and Verification
Prototype units are built to validate the design against application requirements and engineering specifications. Functional testing, performance characterization, environmental evaluation, and design verification activities are conducted to identify opportunities for refinement. Feedback from this stage ensures that risks are addressed before formal qualification begins.
Qualification and Compliance
Following successful verification, the design undergoes rigorous qualification testing to demonstrate reliability and compliance with customer and industry requirements. Testing may include environmental stress screening, vibration, shock, thermal cycling, abuse testing, and performance validation under real-world operating conditions. This process confirms that the product is ready for deployment in demanding. applications.
Regulatory and Certification Support
Ultralife provides comprehensive support for regulatory approvals and product certifications required for market introduction. Our team works with customers and certification agencies to address transportation requirements, safety standards, industry-specific regulations, and product documentation. This streamlined approach helps accelerate time to market while ensuring compliance.
Pre-Production
to full-scale manufacturing, pilot builds are conducted to validate production processes, tooling, work instructions, quality controls, and supply chain readiness. The pre-production phase helps identify and resolve any manufacturing challenges while ensuring consistent product quality and repeatability at volume.
Production
Once production readiness is confirmed, the product transitions into full-scale manufacturing. Ultralife leverages proven manufacturing processes, quality management systems, and rigorous testing procedures to deliver reliable products that consistently meet customer specifications. Continuous monitoring and process control ensure high quality and dependable performance.
Delivery and Debrief
Following production, products are delivered according to customer schedules and logistics requirements. Ultralife collaborates with customers during deployment and initial field use to gather feedback, review performance, and identify opportunities for improvement. This debrief process helps strengthen future product iterations and partnership success.
Lifecycle Support
Our commitment extends well beyond product launch. Ultralife provides ongoing lifecycle support including technical assistance, product enhancements, sustaining engineering, regulatory updates, component obsolescence management, and long-term supply planning. This ensures customers continue to receive reliable support throughout the operational life of their systems.
