Development and manufacturing of custom lithium-ion battery systems with BMS for demanding applications
Air Energy Entwicklungs GmbH & Co KG
Aachen, GermanyNew on Amplifa
About Air Energy
Air Energy Entwicklungs GmbH & Co KG has been developing and manufacturing components for electric drive technology in Aachen since 1992. Its core business is custom battery systems made of lithium-ion cells, including the associated battery management systems (BMS). The service portfolio covers hardware and software development, battery cooling, battery algorithmics, battery enclosure development, and the development of special manufacturing processes. Air Energy delivers ready-to-install energy storage systems with charging and discharging technology, offered with a CCS2 DC charging option for high-voltage battery systems. As a service, copper connectors are welded onto cylindrical cells; welding of aluminium connectors is performed in cooperation with the Fraunhofer Institute for Laser Technology. The scope of services ranges from prototyping, first-article production and commissioning to small-series manufacturing. Fields of application include aerospace, eVTOL, concept and prototype vehicles, autonomous underwater vehicles, offshore and line engineering, mobile robots, and hybrid buses.
- Site
- Aachen
- Processes
- Development and manufacturing of battery packs (lithium-ion), Development of battery management systems (BMS), Development of battery cooling, battery algorithmics and battery enclosures, Custom hardware and software development, Manufacturing of ready-to-install energy storage systems with charging and discharging technology, Welding of copper connectors onto cylindrical cells (service), Welding of aluminium connectors (service, in cooperation with the Fraunhofer Institute for, Prototyping: conception, design, development, first-article production and commissioning
- Materials
- Lithium-ion cells, Copper, Aluminium, Ni-Cd cells (nickel-cadmium), Nickel-cadmium cells
- Founded
- 1992
- Industries
- Aerospace, eVTOL, Concept and prototype vehicles, Autonomous underwater vehicles, Offshore and line engineering, Mobile robots
- 01
Development (hardware, software, BMS)
- 02
Prototyping / first-article production
- 03
Welding of connectors
- 04
Assembly / commissioning
- 05
Small-series manufacturing
Materials & Processes
Lithium-ion cells
Basis of the custom battery packs and high-voltage battery systems with BMS.
Copper
Connector material for cylindrical cells for low-resistance connections; welding offered as a service.
Aluminium
Aluminium connectors enable large cross-sections with small contact surfaces and good mechanical flexibility.
Nickel-cadmium cells
Cell type of the first project AE-1 Silent from 1997.
Locations
Aachen
DEDevelopment and Manufacturing
- Lot size
- Small series
- Materials
- Lithium-ion cells, copper, aluminium
- Laser welding system (connection technology, in cooperation with the Fraunhofer Institute for Laser Technology)
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Development and manufacturing of battery packs (lithium-ion)Assembly | – | – | – | Small series | Lithium-ion cells |
| Development of battery management systems (BMS)Engineering | – | – | – | – | – |
| Development of battery cooling, battery algorithmics and battery enclosuresEngineering | – | – | – | – | – |
| Custom hardware and software developmentEngineering | – | – | – | – | – |
| Manufacturing of ready-to-install energy storage systems with charging and discharging technologyAssembly | – | – | – | – | Lithium-ion cells |
| Welding of copper connectors onto cylindrical cells (service)Joining | – | – | – | – | Copper |
| Welding of aluminium connectors (service, in cooperation with the Fraunhofer Institute forJoining | – | – | – | – | Aluminium |
| Prototyping: conception, design, development, first-article production and commissioningEngineering | – | – | – | Small series | – |
| Manufacturing of high-voltage battery systems with CCS charging option (CCS2 DC)Assembly | – | – | – | – | Lithium-ion cells |
| Development of special manufacturing processesEngineering | – | – | – | – | – |
1 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Laser welding system (connection technology, operated in cooperation with the Fraunhofer Institute | – | – | – | – | – |
Additional services
Reference customers
History
- 1992
Foundation; development and manufacturing of components for electric drive technology.
- 1997
Presentation of the AE-1 Silent, the first self-launching electric glider with Ni-Cd cells.
Battery systems for Solar Impulse I & II, Siemens Extra 330LE and Electra EL-2 Goldfinch.
- 2023
Selected as supplier of the battery system for Dufour Aerospace's hybrid-electric eVTOL Aero2 (October 2023).