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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.

Enhancing MTRS Robot’s MK2 Battery Box Runtime, Reliability, and Capability for DoD


Roadside bombs and other threats place our troops and other responders in harm’s way. Advanced unmanned vehicles and robotics, like the Man Transportable Robotic System (MTRS), play a critical role in removing personnel from dangerous environments by performing tasks without the need for direct human manipulation. In 2008, the Department of Defense (DoD) determined that it needed to extend the run time of its MTRS robots. Instead of purchasing costly replacement components from the original manufacturer, DoD determined it could achieve cost efficiencies by designing a new battery box that could hold additional BB-2590 lithium-ion batteries to extend mission duration.

After developing an initial design, DoD turned to Battelle to produce multiple prototypes within 60 days After Receipt of Order (ARO) for proof of concept testing, implement design for manufacturability improvements to improve productivity and reduce cost, produce over 1900 units to meet an urgent warfighter need, and deliver a complete technical data package to the customer for future competitive procurement.  


Battelle gathered an interdisciplinary team of materials, manufacturing, engineering, and technology-insertion program experts to complete the battery box design for manufacturability, ensure feasibility, and complete production. Battelle began by developing initial production prototypes, which were analyzed and tested. During this process, Battelle identified design enhancements to improve productivity and reduce cost. Once addressed, Battelle delivered the first lot product for DoD testing and received approval. Full-scale production then began at our Dublin, Ohio facility in 2009 and more than 2,700 MK2 battery boxes have been manufactured to date.


Battelle’s team bridged design and manufacturing expertise to deliver an innovative solution that allows DoD to lower overall support costs, improve robot run time, and improve platform capabilities and reliability. The MK2 Battery Box is a robust “smart” power management system for the MK2 robotic platform developed in conjunction with Penn State University’s Applied Research Laboratory. That successful partnership and Battelle’s cost-effective production saves the government money and increases the length of time the battery can operate.