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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. 

Make your complex manufacturing simple.
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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.

Quick, Accurate Threat-Detection Scanner for Liquid, Aerosol, and Gels Eases and Secures Air Travel Worldwide


Each year, more than 640 million passengers board domestic flights in the U.S. alone, according to Research and Innovative Technology Administration (RITA). Given demanding global travel volumes, security procedures must be extremely accurate to ensure safety but also efficient to avoid costly and frustrating travel delays. Bottles and containers made of varying materials, such as glass, plastic, metal, paper, and ceramic, pose a unique challenge for security check-point personnel tasked with quickly distinguishing between benign and harmful substances.


Battelle responded to air travel authority needs by developing one of the most advanced bottle liquid scanners in the world, which can detect and alert security personnel to flammables, acids, and explosive liquids, aerosols, and gels within seconds.

A first-of-its kind technology, Battelle's award-winning LS10 safely, quickly, and accurately detects threat substances, such as flammables, acids, oxidizers, explosive precursors and explosive compounds, within sealed or unopened metal, glass, plastic, paper, and ceramic containers. Unlike other liquid scanners that rely on and are limited by single technology analysis, the LS10 employs Radio Frequency (RF) and ultrasonic technology to non-invasively interrogate liquids and gels in containers. A proprietary data fusion process then combines and analyzes data to alert security personnel of suspicious contents within seconds, while mitigating costly false alarms. 


The LS10 delivers efficient processing with high-detection capability and low false-alarm rate. Depending on the operator, accurate threat detection in clear, colored, and opaque containers can be achieved as quickly as three seconds. As threats continue to evolve, the LS10 allows for easy software upgrades for long-term viability and cost savings.

The LS10 earned the European Civil Aviation Conference’s Type B Liquid Explosive Detection Systems official endorsement and is a candidate for similar approval in the United States.