Stafl Systems
Integrated Engineering Services

 

Stafl Systems engineers help customers build electric vehicles, equipment and energy storage systems, from battery cells to the vehicle controls around them.

Our electrical, embedded software, mechanical and test engineers work as one team, backed by an in-house lab and production floor.

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Unified Product Family & Powertrain Design

Integrated electric powertrain architectures

           
Battery Management
System
 
Battery Pack
 
Stafl Systems engineers design and assemble a fully integrated and expanding ecosystem of products.
These products enable our engineers to design and assemble powertrains that come together faster, with best-in-class efficiency and reliability.

Advanced Energy Storage Testing

Real-world tests to verify performance

 

Cell manufacturers can sometimes be a little optimistic about cell performance data. Stafl Systems has specific testing capabilities to run cells and battery packs through trials, quickly identifying any potential safety issues.

Cell Testing

To refine our BMS algorithms, Stafl Systems submits battery cells to accelerated charge and discharge cycles where we vary the ambient temperature and collect specific cell performance data. This is then logged and analyzed to provide a clear picture of a cell’s true performance.

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Battery Pack Testing

Stafl Systems works with engineering teams to understand thermal management and quickly identify any potential safety issues, and to identify whether a pack is using a true passively-propagation resistant (PPR) design.

Additional Capabilities

Custom Test Equipment

We design and build our own end-of-line testers, hardware-in-the-loop rigs and custom interconnects, and we can build them for your product too.

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Facilities & Capabilities

In-house resources to quickly move projects forward

Our team has tools in-house to offer rapid prototype fabrication, circuit board assembly and battery pack manufacturing.
 

  • FIVE-AXIS CNC
  • 3D PRINTING IN MJF, SLS, SLA, and FDM
  • 48V BATTERY PACK TESTER
  • 1000V 60KW BI-DIRECTIONAL DC POWER SUPPLY
  • TEMPERATURE & ENVIRONMENTAL TEST CHAMBERS
  • 1000W IPG LASER WELDER
  • SMT LINE WITH CONFORMAL COATING

Vertical Integration, ​Streamlined Service

 

Stafl Systems offers mechanical engineering alongside our electrical and software teams to accelerate product development.

Mechanical Engineering

Designed for efficiency and longevity

Stafl Systems' mechanical engineers are well versed in battery technology, product design and thermal management, capable of designing and building fully custom assemblies for clients.

Working alongside electrical, software and industrial design engineers allows for seamless integration of mechanical and electrical components and superior solutions for our clients.

 

Production Support

Transfer to production with our SMT line, test fixtures and work instructions, for low-volume builds or handoff to your contract manufacturer.

Additional Client Services

Optimize your project with added support

Functional Safety Support

Safety concepts, FMEAs and hardware/software partitioning for systems designed to ISO 13849 and similar standards.

Rapid Prototyping

Stafl Systems offers rapid prototyping services to clients as needed, helping bring new projects to life quickly and accelerating the test and evaluation phases. The equipment in the Stafl Systems workshop and engineering labs allows engineers to produce new designs in-house, without needing to wait for custom parts to be produced.

Cell Selection

Independent cell benchmarking against your duty cycle before you commit to a supplier.

Systems Evaluation

Our expert engineers are often requested to conduct evaluations of existing or proposed systems and to offer feedback. Based on this analysis, clients can have a better understanding of the scope required for a larger project or simply receive feedback on existing designs to produce better products moving forward, with or without Stafl Systems' assistance.


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.

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  Insights Video Series
Have you ever wanted to know how a BMS works? Or how lithium-ion batter packs can be used safely in different applications? Our team discusses these topics and more in our Insights video series.
  Careers at Stafl Systems
Are you looking to join a team where your designs can be found in the latest automotive, aerospace, and consumer electronics spaces?

Stafl Systems
Insights Video Series

STAFL SYSTEMS
insights video series

Have you ever wanted to know how a BMS works? Or how lithium-ion battery packs can be used safely in different applications? Erik Stafl, President of Stafl Systems, discusses these topics and more in our Insights video series.   

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ENGINEERING A CLEAN ENERGY FUTURE

 

Stafl Systems solves the most difficult challenges of the modern era of electric and hybrid-electric vehicles. Since 2010, our team has helped the top firms in the industry push the boundaries of technology and performance.

CAREERS AT STAFL SYSTEMS

 

Are you interested in joining a culture by engineers, for engineers? At Stafl Systems we empower our team members to get creative and be directly involved in making impactful decisions.

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