Defence & Aerospace Battery Programs
Selective engagement, ITAR-free BOM where required, traceability you can audit a decade later.
We say no first, and yes carefully.
Defence and aerospace battery work has a different set of consequences from consumer electronics. We engage selectively — only on Li-Po pouch and rechargeable coin-cell programs (the formats we actually manufacture), only on dual-use / non-strategic applications, and only after a customer security review establishes that the end-use, end-user and BOM are compatible with our manufacturing footprint. Programs we'll engage on: ISR sensor packs, soldier-worn health monitors, helmet HUD / camera accessories, hand-held comms accessories, training-system tablets, wearable IFF, deployable environmental sensors. Programs we don't engage on: 18650 / 21700 cylindrical packs (we don't make these), BB-2590 series tactical batteries, weapon-system primaries, missile / munition power, or anything on the US Munitions List or EU Common Military List.
ITAR-free BOM where required.
For programs where the customer's export-control office classifies the end-product as exportable, we can source cathode, anode, electrolyte, separator and tab materials from non-Chinese suppliers — Korea, Japan, EU — and document chain-of-custody with batch numbers retained 10+ years. Our standard catalogue includes Korean LCO from L&F, Japanese Asahi-Kasei separator and Mitsui electrolyte. We are not a DDTC-registered manufacturer and do not act as one.
MIL-PRF-32383 abuse stack.
Defence small-cell programs run a tougher abuse profile than UN 38.3: nail penetration, crush at multiple orientations, projectile impact, thermal shock at -40 °C ↔ +71 °C, vibration and shock per MIL-STD-810G/H, and altitude (low-pressure) testing. STANAG 4569 ballistic classes and DO-160G airborne testing layer on top for vehicle and aviation programs. We run MIL-PRF samples in-house through stage 1; STANAG and DO-160G via certified labs (Element, NTS, TÜV).
Real platforms (anonymised).
| Application | Configuration | Capacity | Standards stack | Region |
|---|---|---|---|---|
| ISR sensor pack (long-loiter, remote) | 1S Li-Po HV LCO, low-SD chemistry | 2,500 – 4,000 mAh | MIL-PRF-32383, low-SD verification | EU NATO |
| Soldier-worn health monitor patch | Single-use thin Li-Po pouch | 80 – 200 mAh | MIL-STD-810H thermal + drop, IEC 60601-1 | EU + APAC |
| Helmet HUD / camera accessory | Curved Li-Po pouch (custom geometry) | 500 – 1,200 mAh | MIL-STD-810H, RTCA DO-160G | EU + APAC |
| Hand-held comms accessory (non-main) | 2S Li-Po pouch + smart BMS (SBS) | 1,500 – 3,000 mAh | MIL-PRF, MIL-STD-810H, AS9100D | EU NATO |
| Tactical training-system tablet | 2S Li-Po pouch + auth + smart BMS | 4,000 – 8,000 mAh | MIL-STD-810H, AS9100D | NATO |
| Wearable IFF / RFID badge | LIR2032 / LIR2450 rechargeable coin | 40 – 120 mAh | MIL-STD-810G, IEC 62133-2 | EU + APAC |
| Sealed environmental sensor (deployable) | ML SMD coin (reflow-mounted) | 40 – 65 mAh | MIL-PRF, hermetic seal verification | EU + Latam |
Programs above all use Li-Po pouch or rechargeable coin formats — the cell types we manufacture. We do not produce 18650 / 21700 cylindrical packs, BB-2590 series, or large-format defence batteries; for those formats the customer's sourcing path is a different supplier. Customers and contract numbers redacted under standard NDA; reference-able programs in the same category available on request after security review.
The audit-ready six.
Defence and aerospace customers expect a paper trail that survives the program. Six commitments form the floor of every engagement.
Customer security review first
Engagement starts with the customer's export control office reviewing end-use, end-user and BOM. Programs failing review do not proceed.
ITAR-free BOM (where applicable)
Korean / Japanese / EU sourcing for cathode, anode, electrolyte, separator. Chain-of-custody documented, lot numbers retained 10+ years.
MIL-PRF + MIL-STD-810G/H
Drop, vibration, thermal shock, low-pressure, nail penetration, crush, projectile. In-house abuse rig for stage 1; certified labs for stage 2.
10-year traceability
Every cell logged on serial — vendor lot, formation profile, IR/OCV at each gate, BMS firmware, weld parameters, final test. Retrievable a decade later.
AS9100D-aligned
Quality system mirrors AS9100D for aerospace tier-1 / tier-2 supply. We are ISO 9001 certified; AS9100D alignment is a deliberate process choice.
NDA + dual-use declarations
Every program covered by NDA before quote. Export-control declarations signed for non-controlled programs; controlled programs require customer authorisation.
What program offices ask first.
What kind of defence programs do you take on?
Dual-use and non-strategic defence: man-portable comms, dismounted soldier electronics, surveillance UAV and ground-robot batteries, ISR sensor packs, training-system batteries, military flashlight / handheld packs. We do not engage on weapon-system primary batteries, missile / munition power, or anything on the US Munitions List or EU Common Military List.
Can you supply ITAR-free or no-China-content?
ITAR-free BOM yes, where the customer's export-control review classifies the program as exportable: cathode, anode, electrolyte and separator from Korea, Japan or EU. "No-China-content" (final assembly outside China) is not something we offer — our manufacturing is in Dongguan.
Which standards apply?
MIL-PRF-32383/3 and /4 (US small-cell / large-cell defence). MIL-STD-810G/H (environmental). STANAG 4569 (ballistic). AS9100D (aerospace QMS). RTCA DO-160G (airborne). UN 38.3 (transport, always).
How long do you keep records?
Serial-number-level traceability retained 10 years minimum (15 if contract requires). Records: cell vendor lot, formation profile, IR/OCV at every QC gate, BMS firmware version, weld parameters per batch, final test data. Retrievable on customer request with chain-of-custody documentation.
Do you sign export-control declarations?
For non-controlled programs (end-product not on USML or EU Common Military List), yes. For controlled programs we engage only after the customer's export-control office issues authorisation. We are not DDTC-registered and do not act as a DDTC-registered manufacturer.
Engineering deep-dives.
UN 38.3 + IEC 62133-2 Walkthrough
The transport & safety standards every program crosses, before MIL-PRF.
Read the guide →The Thermal-Runaway Field Guide
How we screen cells and design packs to fail safely under abuse.
Read more →Shipping Lithium Internationally
IATA, IMDG and ADR for defence and aerospace logistics.
Read more →Have a program to discuss?
First step is a non-disclosure agreement and a security review. Send a one-page program description (no proprietary detail required) and we'll respond within 2 business days.
Initiate Engagement