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Battelle Manufacturing

Our unique process focuses on your unique problems.

Our Process

Whether you need just one prototype or hundreds of thousands of units, Battelle can help you manage your project from early concept through mature production. We understand the unique needs of varying product maturity and have the experience and tools to efficiently provide support across the development and manufacturing continuum.


The number of challenges that can pop up related to manufacturing is nearly endless. We know that everyone has unique needs and varying product maturity to factor into the equation. Regardless of where you are on the development and manufacturing continuum, Battelle can help. 

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Battelle’s Production-Optimized Design (POD) process is a unique take on traditional design for manufacturing. The POD process scales to any production quantity to yield product cost savings during low rate initial production runs as well as long-term recurring production cycles. 

We take a systems engineering approach that most importantly starts with a cooperative effort with the customer and, whenever possible, end-user. From those foundational inputs, we find creative solutions that maintain functional requirements and interchangeability while addressing cost reduction targets – or potentially affecting performance improvements.

Our customer-centric focus is built on proven quality systems and is tailored to your product’s needs. We can help you across the entire product lifecycle, but we also understand each customer has unique preferences and needs, and we can enter and exit at any point.

Diagram showing the steps in the manufacturing process

Here’s our process defined:

Build proof-of-concept units and perform system-level rapid prototyping, develop manufacturability requirements and identify lifecycle cost reduction concepts.

Identify system requirements and manufacturing readiness, support development of a producible technical data package and leverage Battelle’s approved supply chain for input and validation.

Work from limited or early technical documentation, select appropriate prototyping techniques at the system and component levels (3D printing, FDM, SLA, rapid molding), and integrate feedback from Battelle’s manufacturing team.

Pilot Build
Apply our deliberately adaptable facilities and staff scalable systems to maintain quality while achieving cost requirements and employ our pilot stage experience, incorporating ongoing changes.

Volume Manufacturing
Utilize our certified quality management systems (QMS) and carefully approved suppliers to sustainably meet quality and cost, perform rolling incorporation of changes, and maintain a trained manufacturing staff and dedicated project team.

Product Support
Factory scheduled maintenance and refurbishment, customer on-site training or factory training.


3D Printing/Rapid Prototyping
Battelle’s 3D printing/rapid prototyping helps our clients identify product issues they didn’t anticipate early on in the process. That saves them time and money by mitigating risk and guiding investments along the development timeline. Learn more


Our team is experienced and proficient at analyzing systems for manufacturability. By applying Battelle’s unique blend of talent available in-house, including systems engineers, machinists, supply chain specialists and manufacturing engineering, we are able to identify key system improvements to meet cost targets, including several example products like a ruggedized electromechanical power pack, a high-reliability ocean sensor, and a new biological detector. Within those products we have been able to reduce 60 percent of the cost of one complex machined manifold and identify 50 percent cost reductions of a consumable assembly.

Battelle Develops Custom Armor Applications for Commercial Vehicles at Low Cost


In recent years, the U.S. federal government has identified a need for lower-cost armored commercial vehicles. Commercially available platforms – such as pickup trucks, sport-utility vehicles, sedans, and vans – allow military forces to operate in areas without military logistical support. As threats to our national security extend beyond the traditional battlefield, we must leverage technology to enable military forces to fulfill their mission needs.


For more than eight years, Battelle has produced lightweight armored and upgraded vehicles for clients who sought better operational performance and protection. Given our experience in lightweight armor and upgrade design, engineering, manufacturing, and testing, we can produce very cost-effective armored commercial vehicles. One way in which Battelle has successfully produced low-cost vehicles is through implementation of design for manufacturing (DFM) methodologies. Battelle was able to reduce the armor part count on its vehicle design by 40%. 

Other modifications we have made to purpose-built vehicles include: upgraded suspension and braking systems to provide safe and improved handling characteristics for a substantially increased gross vehicle weight rating; reinforced front and rear bumpers with integrated IR flood lights; high-output alternator to operate additional electronics at idle; and comprehensive personnel protection, including opaque and transparent armor solutions.


In addition to improving the overall safety of military operators, Battelle can deliver significant cost savings by implementing world-class design and manufacturing principles that reduce part count without sacrificing safety and functionality. Since our first design in 2004, Battelle has delivered more than 300 commercial vehicles manufactured in our ISO 9001:2008 production facilities.

Today, our commercial vehicle solutions are fully operational and is available for purchase through the General Services Administration (GSA). Our vehicles can range from unarmored to heavily armored and overtly military. Such vehicles are customizable and can support the unique needs of our clients.