Stafl Systems
Battery Packs

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How It Works

Custom lithium-ion packs, from first prototype to production.


Stafl Systems designs and builds custom battery packs for aviation, marine, off-highway, industrial and stationary applications. Every pack is built around a Stafl Systems BMS, using the latest cells from leading cell providers.

HIGH PRECISION & QUICK TURNAROUND

Step 1 Define 2-4 weeks

Requirements, cell selection, architecture concept

Step 2 Design 6-10 weeks

Mechanical, electrical, thermal, BMS firmware

Step 3 Proto­type 4-8 weeks

Build and bring-up of first prototype packs

Step 4 Vali­date 6-12 weeks

Performance, environmental, and abuse testing

Step 5 Produce 8-12 weeks

Pilot build, production tooling, and ramp

First prototype: ~3–5 months
Production-ready: ~6–11 months

Typical durations. Actual timeline depends on program scope, cell availability, and certification requirements.

  • Concept to first prototype in months, not years
  • Design, assembly and test under one roof
  • Cells characterized in our own lab before they go in your pack
  • Packs validated on our 1000 V bidirectional test equipment

 

 

Tailored Performance & Reliability

Stafl Systems designs and manufactures lithium-ion battery packs around your vehicle. Each pack integrates a Stafl Systems BMS for safety, control and monitoring, with mechanical and thermal design built for harsh environments.

  • Highly Integrated Designs
    BMS, power distribution and thermal management engineered into one assembly
  • Built-in Battery Management System

    Sophisticated fault monitoring & CAN communication
  • Passive or Liquid Cooling
    Matched to your duty cycle
  • IP67 Environmental Protection
    High performance seal for harsh environments

SOLUTIONS TO FIT ANY FORM FACTOR

From electric supercars to aircraft, submersibles, and mining equipment, we can design a system from the ground up or work with existing elements to create a functional vehicle using the latest powertrain technology.

Stafl Systems’ engineers leverage sophisticated IP and internal reference designs to help create vehicles that are clean, safe and reliable.

Battery Packs

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Custom Battery Packs 
12 V - 1000 V

  • Integrated precharge and main contactor control circuit

  • Communication with Vehicle Control Unit (VCU) via standard CAN Bus Interface, with multiple supported baud rates

  • Standard output messages include cell voltages/temperatures, pack voltage/current, and fault flags

  • Runs internal balancing or commands received from VCU

  • May be installed externally in appropriately sealed enclosure

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Ready to collaborate?

Are you excited to start a project? Would you appreciate more information about our products and services? Our team is here to help.

Get in Touch

 

precise engineering

Features

  • 12 V - 800 V Pack Designs

  • 1 - 100 kWh Pack Sizes

  • Passive or Liquid Cooling Options

  • IP67 Sealed Enclosure

  • Integrated Stafl Systems BMS

    • Cell Balancing

    • CAN Communication

    • Sophisticated Fault Monitoring

    • State of Charge (SOC), State of Health (SOH), Safe Operating Envelope (SOE)

    • Integrated Isolation Monitoring

  • Built-in Power Distribution Unit

    • Pre-charge Circuit

    • Positive and Negative Line Contactors

  • DC Bus Sync (easily paralleled)

  • LED Indicators

  • Stafl Fleet Ready for Telematics Monitoring

COUNTLESS APPLICATIONS

 

hIGH VOLTAGE

While a vehicle’s power system sees a battery pack as a single, high-voltage battery — charging and discharging the entire battery pack at once — the battery control system must consider each battery’s condition independently.

LOW VOLTAGE

A proper system will continuously monitor important battery parameters for low voltage applications, while dealing with the varying power demands of the many aspects of operation and optimizing the usage of the battery.

stationary storage 

The service life of a battery pack is tied to the weakest battery in the system. In the balancing process, each of the batteries within the string is maintained at optimal voltage levels, eliminating the ill-effects of improper charging.