Frequently Asked Questions
COMPANY AND PRODUCT OVERVIEW
What does Upgrade Energy make?
We design and assemble high-performance lithium battery packs optimized for drones and a variety of other platforms, with an emphasis on low weight and mission-specific performance.
Where are Upgrade Energy battery packs made?
Battery packs are designed and assembled in the United States, with operations in El Segundo, California.
Do you provide technical specifications and datasheets?
Yes, we provide both cell and pack-level datasheets via the website’s Datasheets section, as well as on the corresponding product pages.
What is the difference between GREEN, RED, and GOLD battery lines?
- GOLD (Max Range): Built around ultra–high energy density cells (e.g., Amprius) for longer-duration missions where endurance is the primary objective.
- RED (High Power): Uses high-discharge cells (e.g., Molicel P50B/P30B) for high-thrust and payload-intensive applications requiring higher current delivery.
- GREEN (Value and Range): Built around lithium-ion technology (e.g., Amprius SA10) to balance performance, cost, and weight, typically with lower peak power capability than RED.
BATTERY SELECTION AND MISSION FIT
How do I choose the right battery pack for my drone or mission?
Start with these parameters:
- Voltage requirement (series count / “S” count):
Match the aircraft’s supported pack voltage (e.g., 4S, 6S, 12S). Nominal pack voltage is approximately: Nominal pack voltage ≈ S × 3.6 V (e.g., 12S × 3.6 V = 43.2 V). Ensure your maximum voltage (fully charged) and minimum/landing voltage (end-of-flight) are compatible with your propulsion system, ESCs, avionics, and desired flight characteristics. - Capacity (Ah) and energy (Wh):
Higher energy generally increases endurance but increases mass and may reduce peak power capability depending on cell chemistry and internal resistance. A key metric is gravimetric energy density (Wh/kg), which describes energy relative to weight. - Power draw / current needs:
- For aggressive throttle profiles or heavy payloads, consider RED.
- For maximum flight time with moderate power demand, consider GOLD.
- For balanced cost, range, and weight (typically with reduced peak power), consider GREEN.
How do I know if I’m using the correct battery?
For commercial and government programs, it is often prudent to evaluate 1–2 candidate packs close to the target specification. Qualification should focus on:
- Achieved flight time/endurance against mission requirements
- Ability to support flight dynamics (throttle response, payload performance) without excessive voltage sag or thermal rise
- Total cost per mission (including cycle life expectations and operational constraints)
What are common battery selection misconceptions?
A common misconception is that a lighter battery can always meet the same power requirements. In practice, reducing battery mass often reduces current capability (depending on cell selection and pack design). When power margin is tight, selecting a pack with similar weight but greater capacity can improve the likelihood of meeting current draw and endurance requirements – subject to aircraft CG and integration constraints.
Li-ion VS. LiPo AND PERFORMANCE FUNDAMENTALS
How do Li-ion batteries compare to LiPo batteries?
In general:
- LiPo packs are often optimized for high discharge rate (power delivery).
- Li-ion packs are often optimized for higher energy density (endurance).
Typical energy densities vary widely by design and vendor. As a general reference, high-performance LiPo packs are often around ~200 Wh/kg, while Li-ion cells commonly start above ~220 Wh/kg (and can be significantly higher), with tradeoffs in internal resistance and discharge capability.
Li-ion packs may operate effectively over a broader voltage range and can exhibit more noticeable voltage sag under high load, which requires propulsion systems designed to tolerate lower in-flight voltage. We focus on solutions supporting longer flight durations (e.g., greater than ~15 minutes), where energy density becomes a key driver.
Does energy density change depending on discharge rate?
Yes, battery capacity and delivered energy are rate-dependent. Industry testing commonly references low-rate discharge conditions (often around C/5) for standardized capacity/energy characterization. At higher discharge rates, usable capacity and effective energy density can decrease due to voltage sag, internal heating, and electrochemical limitations.
How do cell manufacturers establish discharge ratings?
Manufacturers typically determine discharge capability based on temperature rise, voltage stability, safety thresholds, and performance degradation under load. Discharge ratings can vary in conservatism across vendors; program-level qualification is recommended when operating near limits.
Why do pack-level power ratings not scale directly with cell discharge ratings?
Cell-level testing occurs under highly controlled conditions (single-cell fixtures, ideal thermal paths). Pack assemblies introduce:
- Higher thermal coupling and reduced heat rejection from interior cells
- Interconnect and contact resistances
- Non-uniform temperature distribution and aging behavior
We apply safety margins and recommend maintaining airflow over the pack where possible to improve thermal management and preserve performance.
THERMAL MANAGEMENT AND OPERATING SAFETY
What is a practical indicator of overheating?
A subjective “too hot to hold” check can indicate overheating, but it is not a reliable control method. Where available, use temperature telemetry (pack sensor or aircraft instrumentation). Typical safe operating limits should follow the cell manufacturer’s specification, and pack design limits should be treated as authoritative.
Why do some batteries include temperature sensors?
Commercial-grade battery systems often include temperature sensing to enable:
- More accurate performance evaluation
- Improved operational safety and mission logging
- Better handling of larger packs where surface temperature may not reflect internal cell temperature
Do the batteries work in cold weather?
Yes, depending on chemistry and cell design. Lower internal resistance chemistries (often aligned with high-power cells) may perform better in cold conditions. Minimum operating temperature should be derived from the cell specification. For best results, pre-warming packs toward room temperature prior to flight can reduce voltage sag and improve available capacity.
MANUFACTURING, JOINING AND TEST EQUIPMENT
How does Upgrade Energy weld batteries?
We use multiple joining technologies, including laser welding. Copper interconnects are substantially more conductive than nickel, reducing resistive losses, heating, and voltage drop; however, copper is not well-suited to traditional resistive spot welding, which drives the selection of alternative joining processes.
What ACIR test device do you use?
We use a Hioki BT3562A battery tester to qualify packs, with calibration performed annually.
What quality checks are performed on battery packs?
Packs undergo visual and electrical checks to verify:
- Weld integrity and workmanship
- Solder quality (where applicable)
- Cell alignment and mechanical fit-up
- Insulation, isolation, and protection features
- Electrical performance verification, including resistance measurements (e.g., ACIR) and voltage checks within specification
SAFETY, COMPLIANCE, AND APPLICATION SCOPE
Are Li-ion batteries safe?
Li-ion batteries are safe when used within specification and handled properly. Key precautions include:
- Avoiding overcharge, over-discharge, and overheating
- Ensuring cells remain balanced (especially for series packs)
- Inspecting packs for mechanical damage (including crash damage) before use
- Following product-specific electrical limits and handling guidance
- Disposing or recycling packs in accordance with applicable regulations at end of life
Are your products NDAA compliant?
Yes, our batteries are NDAA compliant.
Do your batteries work in non-drone applications?
Yes, packs can be used in applications such as educational robotics, ground robotics, and marine platforms. Because we optimize for weight, customers should evaluate durability requirements, cooling/airflow availability, mounting approach, and environmental exposure for non-UAS use cases.
I need a custom battery solution—can you help?
Yes, we develop custom battery systems across a wide range of aircraft scales. Use the Contact Us page to submit project requirements. Depending on engineering capacity and scope, responses are typically provided within 1–2 weeks with next steps.
ORDERING, SHIPPING, LEAD TIMES, AND SUPPORT
Do you offer accessories (connectors/adapters)?
Yes, accessories such as AMASS connectors and series adapters (e.g., XT60/XT90 series and parallel adapters) are available on the Products page on our website.
What is the typical lead time?
Lead times vary based on demand and build volume. Some products may have longer lead times. Customers should email support@upgradeenergytech.com to confirm current lead times and whether expedited options are available.
How do you ship orders?
Orders typically ship via FedEx, UPS, and DHL.
Do you ship internationally?
Yes, we ship internationally to most regions (subject to carrier and destination restrictions for lithium batteries).
Can I expedite my order?
Expedited options may be available in some cases. Customers should email support@upgradeenergytech.com to request expediting.
How do I request a quote for government or wholesale purchases?
Requests for quotes and purchase orders can be sent to: sales@upgradeenergytech.com
US Gov UEI Code: HDWKYZ7J8HR6 | 889 PDF Link | NAICS Code: 335911
How can I contact Upgrade Energy?
Customers can contact us via support@upgradeenergytech.com and address listed on the Contact page.
WARRANTY, RETURNS, EXCHANGES, AND CANCELLATIONS
What warranty do you offer?
We offer a 3-month warranty covering defects.
What is your exchange policy?
Exchanges of new products are accepted within 2 weeks, subject to a 10% restocking fee.
What is your cancellation policy?
Orders cancelled after 48 hours are subject to a 25% cancellation fee, as packs are made to order.
What is your return policy?
Returns are accepted within 2 weeks with a 30% restocking fee to cover inspection and performance evaluation.
How do I return an item?
Ship to:
Attn: Returns
Upgrade Energy
145 Sheldon Street
El Segundo, California, 90245
Order number must be included in the return package.
