Inside Our Battery Manufacturing Process: From Modules to Packs

At Proterra, our battery manufacturing process is designed for precision, efficiency, and reliability. From the initial module build to final battery pack assembly, every step is guided by automation, skilled craftsmanship, and rigorous testing. Here is a closer look at how we bring high-performance battery solutions to life.?

Module Build?

Our battery manufacturing journey begins with sourcing high-quality raw materials, including battery cells, thermal interface materials, and structural components. These materials form the foundation of our battery modules, ensuring reliability and efficiency.?

The module build process is highly automated, allowing for consistent, high-quality production with minimal variation.??

The process includes:?

• Assembling Blocks – Precisely arranging battery cells into precision-engineered carriers and assembling them into unified energy blocks. The geometric configuration serves as a key passive safety feature, meticulously engineered to enhance protection and reliability.?

• Establishing Electrical Connections – Building parallel and series circuits between cells to maximize energy transfer efficiency while delivering optimal power density.?

• Battery Management – Integrating advanced sensor arrays that continuously monitor humidity, voltage, temperature, and other critical parameters to ensure optimal battery health and performance at the module level.?

• Functional Testing – Conducting electrical, mechanical, and thermal tests to verify performance, safety, and reliability before modules move on to the next stage—battery pack assembly.?

Battery Pack Assembly?

Once the modules are built and verified, they move into battery pack assembly, where our skilled team members construct the final battery pack.??

The process includes:?

• Building the Enclosure – Constructing a robust housing to protect and seal internal components.?

• Adding Modules – Precisely position and secure energy modules within this architecture. These modules are electrically connected in series to build the pack voltage required for heavy-duty applications. Our design ensures optimal energy distribution, safety, and performance, delivering a robust and scalable battery system.?

• Systems Integration: Our team carefully integrates critical components from establishing the high-voltage chain, integrating the cooling system, to connecting advanced battery management components.?

• Testing: Conducting comprehensive quality checks to verify performance, safety, and compliance before shipment.

Delivering High-Performance Battery Solutions?

By combining automation, advanced manufacturing techniques, and rigorous quality control, we produce battery solutions that are designed to perform in the most demanding environments. Our manufacturing process ensures full traceability, allowing us to track every component from sourcing to final assembly, ensuring reliability and compliance with industry standards. At Proterra, we do not just build batteries—we build the future of electrification.?