Development and manufacturing of custom battery packs and battery charging systems for OEMs, up to 100,000 packs per week.
Alexander Battery Technologies
Peterlee, County Durham (UK) · Frankfurt am Main (DACH office)New on Amplifa
About Alexander Battery Technologies
Alexander Battery Technologies (ABT) is a manufacturer specializing in custom battery packs for OEMs. The company develops and manufactures custom, platform-based and build-to-print battery packs based on lithium-ion, LiFePO4, lithium-polymer, NiMH and NiCad, including cylindrical cells (18650, 21700) as well as associated battery management systems and chargers. Manufacturing at the Peterlee site (North East England) comprises 60,000 sq ft of configurable production space, laser, resistance and micro-TIG welding technology, ultrasonic sealing, semi-automated assembly, and twelve test and development laboratories for projects up to 800 V and over 100 kWh. Capacity: up to 100,000 battery packs per week or flexibly up to 100,000 units per month. Customer industries include, among others, medical technology, aviation/UAV, robotics/AGV, e-mobility, telecommunications, test & measurement, marine/subsea and home & garden. With more than 15 million battery products delivered and over 40 years of experience, ABT supplies OEMs worldwide; for the DACH market, the company maintains an office of Alexander Battery Technologies GmbH in Frankfurt am Main.
- Site
- Frankfurt am Main
- Processes
- Battery Pack Manufacturing and Assembly (contracted battery pack manufacturing, build-to-print and, Battery Pack Design (Custom Battery Pack Design, Core, Core+, TotalCustom), Laser welding of battery cells (IPG EV Flex automated laser welding), Resistance welding of battery cells, Micro TIG welding of battery cells, Ultrasonic sealing, Semi-automated and automated battery pack assembly, Battery pack and cell testing, cycling and validation (in-house)
- Materials
- Lithium-Ion (Li-ion), NiMH (Nickel-Metal Hydride), LiFePO4 (Lithium Iron Phosphate), Lithium Polymer, 18650 Cylindrical Cells, 21700 Cylindrical Cells, NiCad, Lithium-Ion
- Certificates
- ISO 9001, ISO 45001, Cyber Essentials, WEEE Compliance (Membership), ISO 13485, IATF 16949, ISO 14001
- Founded
- 1984
- Industries
- Medical Technology, Aviation & UAV (Drones, eVTOL), Robotics/AGV/AMR, E-Mobility, Marine/Subsea, Home & Garden
- 01
Battery Pack Design (Engineering, BMS, Chargers)
- 02
Prototyping and Cell/Pack Testing
- 03
Procurement and Supplier Qualification (PPAP)
- 04
Cell Interconnection (Laser, Resistance, Micro-TIG Welding)
- 05
Assembly and Ultrasonic Sealing
- 06
End-of-Line Testing and Validation
- 07
Regulatory Approvals (e.g. UN 38.3, IEC 62133, UL2054)
- 08
Volume Manufacturing and Long-Term Supply
Cell chemistries and processes
Lithium-Ion
Standard chemistry for high energy density, used among others in medical technology, UAV and e-mobility.
Lithium Iron Phosphate
Safety-oriented chemistry, frequently used in stationary and industrial applications.
Lithium-Polymer
Flexible form factors for space-critical OEM applications.
Nickel-Metal Hydride
Proven chemistry for existing product designs.
Nickel-Cadmium
Historical origin of the business, still in the portfolio for legacy applications.
Cylindrical Cells
Industry-standard cell formats for scalable pack architectures.
Sites
Peterlee, County Durham
UKHead Office, Production and Manufacturing Site, Battery Technology Centre
- Lot size
- up to 100,000 packs/week; flexibly up to 100,000 units/month
- Materials
- Li-ion, LiFePO4, Li-Polymer, NiMH, NiCad
- IPG EV Flex laser welding system (2024)
- Configurable battery pack production lines
- Programmable welding systems
- Ultrasonic sealing systems
- Micro-TIG and resistance welding systems
- Semi-automated assembly systems
- Product-specific test equipment
- 12 test and development laboratories (up to 800 V, >100 kWh)
- 20,000 sq ft warehouse with buffer stock programs
Frankfurt am Main
DESales and service office DACH (Alexander Battery Technologies GmbH)
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Battery Pack Manufacturing and Assembly (contracted battery pack manufacturing, build-to-print andAssembly | – | – | – | 100,000 packs per week (~400,000/month) | Lithium-Ion, NiMH, LiFePO4, Polymer, 18650 cells, 21700 cells, Cylindrical cells |
| Battery Pack Design (Custom Battery Pack Design, Core, Core+, TotalCustom)Engineering | – | – | – | – | Lithium-Ion, NiMH, LiFePO4, Polymer |
| Laser welding of battery cells (IPG EV Flex automated laser welding)Joining | – | – | – | – | Lithium-Ion cells, LiFePO4 cells |
| Resistance welding of battery cellsJoining | – | – | – | – | Lithium-Ion cells, NiMH cells |
| Micro TIG welding of battery cellsJoining | – | – | – | – | Lithium-Ion cells |
| Ultrasonic sealingJoining | – | – | – | – | Plastic (battery pack components) |
| Semi-automated and automated battery pack assemblyAssembly | – | – | – | – | Lithium-Ion, NiMH, LiFePO4 |
| Battery pack and cell testing, cycling and validation (in-house)Testing | – | – | – | – | Lithium-Ion, NiMH, LiFePO4 |
| Battery Management System (BMS) design and developmentEngineering | – | – | – | – | Lithium-Ion, LiFePO4 |
| Custom battery charger design and developmentEngineering | – | – | – | – | Lithium-Ion, NiMH |
| Battery pack development up to 800V and >100kWh (12 development laboratories)Engineering | – | – | – | – | Lithium-Ion, LiFePO4 |
8 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Automated laser welding system for battery cells | IPG EV Flex | 1 | – | 2024 | Peterlee, County Durham, UK |
| Configurable battery pack production lines | – | – | 60,000 sq ft manufacturing space | – | Peterlee, County Durham, UK |
| Programmable welders | – | – | – | – | Peterlee, County Durham, UK |
| Ultrasonic sealers | – | – | – | – | Peterlee, County Durham, UK |
| Semi-automated assembly systems | – | – | – | – | Peterlee, County Durham, UK |
| Product-specific test equipment | – | – | – | – | Peterlee, County Durham, UK |
| Micro TIG welding equipment | – | – | – | – | Peterlee, County Durham, UK |
| Resistance welding equipment | – | – | – | – | Peterlee, County Durham, UK |
Additional services
Reference customers
Quality
Manufacturing is certified to ISO 9001 and ISO 45001. Quality assurance includes DFMEA/PFMEA, control plans, PPAP supplier qualification, IQ/OQ/PQ validation, SPC, CAPA processes, full material and build traceability via an IFS ERP system, as well as in-house cell and pack testing and cycling; documented defect rate of 0.04%.
| Evidence | Peterlee |
|---|---|
| ISO 9001 | |
| ISO 45001 | |
| ISO 13485 | |
| IATF 16949 | |
| ISO 14001 |
History
- 1967
Founding of Alexander Technologies Inc in Mason City, Iowa, USA
- 1984
Founding of Alexander Technologies Europe Ltd in the UK on 16 May; focus on two-way communication and biomedical batteries/chargers (NiCad, NiMH)
- 1997
Relocation in September to Doxford Drive, South West Industrial Estate, Peterlee
- 2004
Delivery of the first lithium-ion battery pack
- 2019
Acquisition by Shard Credit Partners on 5 September
- 2020
Opening of the new manufacturing facility and expanded warehouse (+40,000 sq ft)
- 2022
Renovation of the original building (Unit 4) into the Battery Technology Centre
- 2023
Opening of the Battery Technology Centre (May) with 12 R&D laboratories as well as the DACH office in Frankfurt am Main
- 2024
Installation of the automated IPG EV Flex laser welding system