Battery Engineering for Demanding Flight and Robotics Applications
From rapid prototypes to production-ready battery systems, Upgrade Energy designs and builds custom power solutions for aircraft, industrial drones, robotics, and specialized unmanned platforms.
What Do We Engineer
Upgrade Energy develops custom battery systems for demanding flight and robotics platforms where performance, integration, reliability, and manufacturability are critical.
Aircrafts & Unmanned Systems
Industrial & Agricultural Drones
Robotics & Autonomous Platforms
Our Engineering Capabilities
Our team develops custom battery systems that combine electrical, thermal, software, and mechanical design into application-specific solutions built for real-world performance.
Battery Design
Custom lithium battery pack design tailored to application requirements including voltage, capacity, energy density, weight, runtime, and power output.
Thermal
Thermal design and heat-management strategies to support safety, reliability, and sustained battery performance in demanding operating environments.
Power Distribution
Integrated power distribution solutions for efficient energy delivery, system stability, and reliable operation across connected subsystems.
Software
Battery software and smart battery integration for monitoring, diagnostics, communication, control, and platform-level system compatibility.
Electronics
Custom electronics development including BMS, PCB design, sensing, protection, and intelligent battery controls for advanced battery systems.
Enclosure
Mechanical and enclosure design for packaging, environmental protection, integration, durability, and serviceability in constrained platforms.
Our Featured Custom Battery Projects
Upgrade Energy has supported a wide range of custom battery and electronics projects across commercial drone, UAV, and robotics applications.
6s 10Ah Smart Battery (V1 & V2)
Smart battery pack built around Samsung 50S cells with integrated BMS, active cooling, and carbon fiber case. The BMS includes standard protections including overvoltage, overcurrent, short circuit detection, overtemperature, and undertemperature. Pack voltage, cell voltage, temperature, current and more are reported over DroneCAN.
6S 3Ah Carbon Case Battery
This battery features a durable carbon fiber case which allows airflow to pass through the battery, ensuring low operating temperatures and drop protection.
Skydweller Aero Battery
The Skydweller Aero project featured a several hundred kilowatt-hour capacity, enabling the 72 meter wingspan aircraft to remain in continuous flight for up to 30 days.
6S 22.2Ah Amprius SA08 Smart Battery
This 6s 22.2Ah Amprius SA08 smart battery product featured a hard case for drop protection, air cooling for improved operating performance, and DroneCAN communication.
Our Development Process
1.
Requirements Review
We begin by understanding your platform, mission profile, power needs, integration constraints, and development goals.
2.
System Architecture
Our team develops the battery, electronics, software, thermal, and enclosure approach to fit your application.
3.
Prototype Validation
We build and refine prototypes for form, fit, function, safety, and performance.
4.
Production Support
Once validated, we support repeatable builds and production deployment, backed by our 18,000 sq. ft. facility, with capacity for 10,000+ batteries per month.
Let’s Build Your Next Battery System
