Re:Build Battery Solutions designs, develops, and manufactures advanced lithium-ion battery systems and the production infrastructure that enables scalable energy manufacturing in the United States. As part of Re:Build Manufacturing, we combine deep engineering expertise, precision manufacturing, and system integration to accelerate innovation and strengthen domestic supply chains.
Our core capabilities include battery module and pack development, battery management system (BMS) design, and production line engineering. We design and build custom battery modules and packs optimized for safety, performance, and manufacturability across demanding applications such as mobility, defense, industrial, aerospace, and robotics. Our multidisciplinary team integrates mechanical, electrical, software, and thermal engineering with in-house manufacturing and automation expertise to deliver complete, production-ready energy systems.
We also design and deploy automated production lines and factory infrastructure that make battery manufacturing scalable, safe, and efficient. This includes pilot lines, assembly automation, and turnkey factory systems for advanced chemistries such as solid-state and high-energy-density lithium-ion. By merging product and process expertise within one organization, we help customers reduce risk, shorten development cycles, and ensure consistent quality from prototype through high-volume production.
Our 175,000-square-foot facility in New Kensington, Pennsylvania serves as the hub of our operations. The site is AS9100-certified and ITAR-compliant, with 15 megawatts of power, on-site rail access, and full digital traceability to support regulated and mission-critical applications. The facility supports the full manufacturing lifecycle from prototyping and pilot production to commercial-scale deployment and is expandable to over 750,000 square feet to meet future demand.
Re:Build Battery Solutions leverages a secure and resilient U.S.-based supply chain, sourcing cells and materials through domestic partners that align with national energy and manufacturing policy objectives. Our design-for-manufacturing approach and standardized module architectures help customers accelerate time to market while lowering non-recurring engineering (NRE) costs.
In addition to proprietary battery technologies, our team develops custom and off-the-shelf BMS solutions that provide modular firmware, flexible hardware architectures, and advanced diagnostic and communication capabilities. We apply rigorous DFMEA and PFMEA methodologies and design to meet standards such as UN 38.3, UL 2054, UL 1973, UL 2580, and ISO 26262 to ensure compliance across mobility, defense, and energy storage applications.
Re:Build Battery Solutions bridges the gap between engineering innovation and scalable production. Through Re:Build Manufacturing’s nationwide ecosystem of companies in automation, precision machining, composites, and system integration, we deliver vertically integrated, end-to-end solutions that turn concepts into commercial realities in the United States.
From prototype battery packs to fully automated manufacturing systems, Re:Build Battery Solutions provides the technology, infrastructure, and expertise that power the next generation of electrification.
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