Design and Manufacture of Custom Battery Packs.

IONETIC designs and manufactures custom battery packs for vehicle manufacturers across automotive, bus, marine, commercial and off-highway. We work with companies producing roughly 100 to 15,000 units per model per year, where an off-the-shelf pack would compromise the vehicle's packaging, performance or economics. IONETIC is a single integrated technology partner that handles everything from concept to production, producing custom battery systems 10x lower cost and 4x faster than traditional solutions.

IONETIC is a UK battery pack designer and manufacturer, with a battery fabrication and industrialisation centre, Arc Fab Pilot, in Brackley, Northamptonshire, and an R&D and battery pack development lab in London. Our quality management system is certified to ISO 9001:2015 by BSI for the design and manufacture of battery systems for propulsion and energy storage applications.

IONETIC does not publish fixed pack prices, because cost depends on energy, chemistry, cell format, annual volume and how much integration work the vehicle needs. What can be said precisely is the shape of the cost. A custom programme has traditionally meant development costs out of reach of all but the largest global OEMs, because a bespoke pack has meant bespoke tooling, a bespoke validation programme, and the capital cost of a dedicated production line spread across low volume. Pre-validated architectures and shared production processes remove those phases, so a customer buying hundreds or thousands of units reaches a cost base built on far more. That is how a genuinely custom pack becomes affordable at low and mid volume. Tell us the vehicle and the volume and we will give you a real number.

With IONETIC, as little as 9 months from requirements to production, and 8 to 12 weeks to a first prototype. A traditional ground-up programme takes considerably longer because every subsystem is designed and validated from scratch. Three things compress it here: we start from architectures that are already engineered and validated, our software automates design and simulation work that otherwise takes months of manual engineering, and every design is linked to our manufacturing process from day one, which removes the redesign loop that usually follows a first prototype build.

An off-the-shelf pack is the right answer when the vehicle can be designed around it. The moment the pack starts dictating floor height, mass distribution, usable interior space or where the vehicle's structure has to run, you are paying for it somewhere else in the programme. A custom pack is shaped to the vehicle instead. Historically the trade was cost and time against fit, which is why most low and mid volume manufacturers accepted the compromise. A platform approach removes that trade, because the custom pack becomes a configuration of a pre-validated architecture rather than a new development programme.

Everything from first concept through production to after-sales, under one contract. In practice that means requirements definition and cell selection, pack design and simulation, prototype build, validation and homologation support, vehicle integration, and series manufacture on our own line. Nominating separate design, engineering and manufacturing partners adds cost, project management overhead and risk, and leaves the interfaces between those partners as the vehicle manufacturer's problem. With IONETIC there is one point of contact, one cost and one warranty.

Our platform is built for vehicle manufacturers producing roughly 100 to 15,000 units per model per year. That is the volume band where a fully bespoke development programme has traditionally been unaffordable, but an off-the-shelf pack forces real compromises on the vehicle. If you sit outside that range, it is still worth a conversation, because the constraint is usually the programme rather than the number.