Acculon Energy


Clients who leverage Acculon’s design solutions for their specialized lithium battery module and pack development program benefit from Acculon’s expertise and experience in designing optimized, safe, and efficient battery packs. The design process involves collaboration between our client and the design team to incorporate the client’s requirements, application needs, and desired performance outcomes into the final battery pack design.

System Architecture

Design solutions start with defining the overall system architecture of the battery module and pack. This includes determining the arrangement and configuration of individual battery cells, interconnections, thermal management system, electrical components, and safety features. The Acculon design team considers factors such as energy capacity, voltage, form factor, and the specific application requirements provided by our clients.

Electrical Design

The electrical design incorporates all the electrical characteristics, features and parameters of the battery pack. This includes selecting appropriate battery management systems (BMS), protection circuits, voltage regulation, current sensing, and balancing mechanisms. The Acculon design team ensures that the electrical design meets our client’s requirements for voltage range, power output, and efficiency.

Mechanical Design

The mechanical design focuses on the physical aspects and packaging of the battery module and pack. The design team considers factors such as size, weight, form factor, mounting options, and mechanical compatibility with the client’s application. Acculon utilizes computer-aided design (CAD) software to create 3D models and optimize the layout to maximize space utilization, ease of assembly, and thermal management.

The lithium-ion battery market is projected to reach
USD $187.89 Billion by 2030, growing at a CAGR of 15.70%
from 2023 to 2030.
0 %
The global off-highway electric vehicle market size was worth around USD 16.91 billion in 2022 and is predicted to grow to around USD 97.8 billion by 2030.
$ 0 B.
Batteries for mobility applications, such as electric vehicles (EVs), will account for the vast bulk of demand
in 2030—about 4,300 GWh.


A well-designed energy storage solution can enhance user adoption, maximize efficiency and safety, minimize environmental impact, and pave the way for widespread electrification, ultimately driving the transition to clean and renewable energy sources.

By harnessing the diverse expertise of Acculon’s engineers and technicians, our innovative approach to design fosters cutting-edge solutions.

Thermal Management

Thermal design is critical for lithium battery packs to ensure optimal performance and safety. The design team incorporates thermal management strategies such as heat sinks, thermal interface materials, cooling channels, and temperature sensors to regulate and dissipate heat generated during battery operation. Maintaining the battery pack within the appropriate temperature range prevents degradation and even thermal runaway.

Safety Considerations

Designing a safe battery pack is of paramount importance. The design team incorporates safety features such as overcurrent protection, overvoltage protection, short circuit protection, and cell-level monitoring to mitigate potential risks and ensure safe operation. Compliance with relevant safety standards and regulations is a crucial aspect of the design process.  Standards, such as UL 2580, UN 38.3, IEC 62133, IEC 62485, UL 1642, ISO 12405, ISO 15194 (and more), and compliance with those standards may vary depending on the specific application, region, and regulatory requirements.

Optimization and Simulation

The design team utilizes advanced modeling and simulation tools to optimize the battery pack design. Acculon analyzes various factors such as energy efficiency, power output, cycle life, and thermal performance through simulations. This iterative process helps refine the design to meet the desired performance criteria and application-specific requirements.

Documentation and Design Validation

Throughout the design phase, the design team creates comprehensive documentation that includes design specifications, schematics, wiring diagrams, component lists, and assembly instructions. Acculon performs design validation activities such as prototyping, testing, and analysis to ensure that the designs meet the specified requirements and performance expectations.