ABS FACILITIES

American Battery Solutions (ABS) is a leading provider of advanced battery technology for a wide range of industrial and commercial applications. With locations in Lake Orion, Michigan, Hudson, Massachusetts, and Springboro, Ohio, we offer a comprehensive range of capabilities and services to support the development and production of lithium ion batteries.

Lake Orion, MI
Springboro, OH
Hudson, MA

Lake Orion, Michigan

Lake Orion, Michigan - Battery Innovation Center

Headquarters, Testing, Engineering, Prototyping, and Support Functions

American Battery Solutions operates out of our Lake Orion Battery Innovation Center where we develop and validate world-class batteries. ABS's Battery Innovation Center was built for the purpose of developing batteries back in 2002. The facility has housed the teams who have developed the NiMh battery cells and packs that power General Motors, BMW and Daimler and the team that developed the Fiat e500 batteries. ABS has expanded the already significant capabilities of the facility. ABS capabilities include:

  • 120,000 Sq. Ft.
  • ISO 9001-2015 certified
  • Cell, module and pack testing
  • Low voltage prototype line
  • High voltage prototype line
  • 300 channels of cell testing
  • 40 channels of module testing
  • 40 channels of pack testing
  • 960 Sq. Ft. of pack thermal chambers
  • Module vibration testing
  • Safety bunkers
  • Hardware in the loop (HIL) lab
Development

Development Capabilities

ABS develops products from concept to full production with our extensive in-house and partner capabilities.

  • Thermal system development
  • BMS software and hardware development
  • Mechanical system development
  • 3D modeling (SolidWorks)
  • Life-cycle model development

Prototyping

Prototyping Capabilities

Two prototype lines integrate a manufacturing execution system to build A-and B-sample prototypes in a highly automated method.

  • 100% automated cell inspection and testing
  • Laser ablation of cells and current collector weld areas
  • Wire-bonding and laser welding
  • Automated thermal interface material dispense
  • Thermal propagation protection foam injection
  • Module and pack end of line testing
Testing

Testing Capabilities

ABS can manage full DVP&R testing, concept verification testing, design of experiments, and full cycle testing of cells, modules and packs.

  • 300 channels of cell testing (0-5V)
  • 40 channels of module testing (0-100V)
  • 40 channels of pack testing (0-1,200V)
  • Module vibration testing
  • HIL testing

Springboro, Ohio

Springboro, Ohio

Advanced Battery Manufacturing Center

ABS’ Advanced Battery Manufacturing Center has been building high voltage batteries for 20 years. Starting with NiMh cells and packs for BMW, General Motors and Daimler and later building all of the Fiat e500 battery packs. That makes this one of the longest running electric vehicle battery manufacturing facilities outside of the vehicle OEMs. Today the facility continues that legacy, building ABS’ ProLiance and Alliance family of battery packs with the same automotive quality as in early programs. 

  • 170, 000 Sq. Ft. facility
  • ISO 9001-2015 certified
  • IATF1649 planned for 2023
  • 3 production lines
  • 2GWh installed capacity (2023)
  • 7-8GWh capacity (2026)
  • Historically zero PPM quality performance
High Voltage Battery Manufacturing

High Voltage Battery Manufacturing

The ABS Advanced Battery Manufacturing Center has capability of installing up-to 50,000 electric vehicle battery packs per year when at full capacity. Our high voltage manufacturing lines are designed to be flexible to accommodate various high voltage pack designs.

  • Installed capacity of 6,200 electric vehicle battery packs per year
  • Full part traceability
  • Automated wire bonding
  • Brick and module assembly line
  • PLC-controlled HMI work instructions
  • Torque controls
  • High voltage protections
  • EOL BMS and pack testing

High Voltage Battery Manufacturing
High Voltage battery Manufacturing
Low Voltage Battery Manufacturing

Low Voltage Battery Manufacturing

ABS's low voltage battery line integrates all of the same automotive quality systems as our high voltage lines. Capable of building any of our Alliance family of low voltage products.

  • 18,000 modules per year capacity
  • 100% automated cell inspection and testing
  • Plasma treatment of cells and current collector weld areas
  • Laser welding or wire bonding
  • Vibration welding of the lid
  • Leak testing
  • EOL testing

Hudson, Massachusetts

ESS Division, Engineering, etc.

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Learn more about ESS
Testing

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Prototyping

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Development

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Our facilities

World class battery engineering and manufacturing