15 Questions for Assessing a Manufacturer’s R&D Depth in Li-Po Technology
We get a lot of “custom” battery projects at Hanery that aren’t really custom at all. A potential client will come to us with a competitor’s so-called custom pack, and when our engineers perform a teardown, we find a standard, off-the-shelf Li-Po cell surrounded by foam blocks inside a large plastic case. The only thing custom about it is the enclosure. This is a story we see time and time again: a product’s potential is being hamstrung by a supplier whose “customization” is only skin-deep. They are assemblers, not innovators.
The difference between an assembler and a true R&D partner is the difference between a product that is merely functional and one that is exceptional. An assembler can put parts together. An R&D partner can manipulate the laws of chemistry and physics to create a power source that is perfectly optimized for your product’s unique demands. They can make it lighter, smaller, more powerful, and longer-lasting. They can solve the complex challenges of thermal management, system integration, and long-term reliability that are the hallmarks of a world-class industrial, medical, or consumer device.
This guide is designed to give you the tools to peel back the marketing layer and assess the true R&D depth of a potential manufacturing partner. These are the 15 questions that our most sophisticated OEM partners ask us during their vetting process. They are the questions that go beyond the datasheet and probe the very culture of a company—its engineering discipline, its problem-solving capabilities, and its vision for the future. Answering them will give you a clear-eyed view of whether you are about to hire a pair of hands or partner with a brain trust.
Table of Contents
1. How do you approach designing a custom-shaped cell from the ground up?
This is the ultimate litmus test. The vast majority of “custom” suppliers are pack assemblers who are limited to the catalog of standard rectangular cells they can buy on the open market. A true R&D powerhouse can engineer the cell itself.
What a 'No' Answer Sounds Like
A supplier with no real R&D depth will immediately try to steer you back to their standard cell list. They’ll say, “A custom shape is very expensive and difficult, let’s look at one of our existing sizes that might fit.” This is code for “We can’t do it.”
What a 'Yes' Answer Looks Like
A capable partner will embrace the challenge and describe their process. We would explain how our R&D team uses your 3D CAD files to model the available internal cavity of your device. We would discuss the DFM (Design for Manufacturability) process for creating a custom cell, including the NRE costs for new cutting dies and forming molds. We would talk about how we can create curved, L-shaped, ultra-thin (<2mm), or other non-rectangular forms to maximize every cubic millimeter of space in your product. A supplier who can have this conversation is a supplier with genuine, cell-level engineering capability.
| Capability | Standard Assembler | True R&D Partner (Hanery) |
|---|---|---|
| Cell Design | Limited to standard rectangular catalog | Fully custom shapes (curved, thin, irregular) |
| Process | Provides a list of what they can buy | Collaborative 3D modeling and DFM analysis |
| Tooling | None | Transparent NRE for custom tooling |
| Outcome | Your product design is compromised | The battery is optimized for your design |
2. What is your in-house BMS hardware design capability?
The Battery Management System (BMS) is the pack’s brain. A supplier’s approach to the BMS is a powerful indicator of their electronic engineering depth.
The Red Flag: Reliance on Off-the-Shelf Boards
A low-tier supplier will say, “We have several standard BMS boards you can choose from.” This means they have a limited set of off-the-shelf protection circuits they buy from a third party. You are forced to choose the “least bad” fit for your product, which may not have the right protection thresholds or the right physical footprint.
The Green Flag: Custom PCB Layout and Component Selection
A strong R&D team will ask, “What are your specific requirements?” They will have an in-house team of electronic engineers who can design a custom BMS from a blank slate. They will talk about their EDA software (like Altium Designer or Cadence), their process for schematic capture, PCB layout, and their ability to create a board that is the perfect size and shape for your battery pack. They will discuss component selection, such as choosing specific MOSFETs with a low Rds(on) to minimize heat or an automotive-grade microcontroller for high-reliability applications.
3. How deep does your BMS firmware and software customization go?
If the BMS hardware is the brain, the firmware is the intelligence. A supplier who can’t control the code cannot create a truly “smart” battery.
Evaluating Firmware Engineering Depth
Ask the supplier: “Can you develop custom firmware for the BMS?” A weak supplier will say their boards are pre-programmed and cannot be changed. A strong partner will ask for your desired parameters and describe their development process. Our firmware engineers, for example, write custom C/C++ code to:
- Tune Protection Thresholds: We can fine-tune the over-current detection delay to accommodate your motor’s specific in-rush profile.
- Implement Custom Charge Algorithms: We can create unique charging profiles to optimize for speed or for maximum cycle life.
- Develop Communication Protocols: We can program the BMS to communicate with your host device using I2C, SMBus, HDQ, or CAN bus, providing a rich stream of real-time data.
- Create Advanced Fuel Gauging Algorithms: We can implement and calibrate sophisticated Coulomb counting algorithms (like Texas Instruments’ Impedance Track™) for a highly accurate State of Charge (SoC) display.
A supplier who can engage at this level is a true embedded systems expert.
4. What is your methodology for thermal modeling and management?
For a high-performance Li-Po battery, heat is the primary enemy of both safety and longevity. A supplier’s approach to managing heat is a direct measure of their R&D maturity.
Moving Beyond a "Wait and See" Approach
An amateur supplier will build a pack and then see if it gets too hot during testing. This is a reactive and inefficient approach.
The Power of Proactive Simulation and Design
A professional R&D team will model the thermal behavior before the first prototype is ever built. Ask: “What simulation tools do you use for thermal analysis?” A sophisticated partner will use Finite Element Analysis (FEA) software (like Ansys or COMSOL) to simulate the heat generated by the cells and BMS under your specified load conditions. This allows them to proactively design a thermal management solution, which could include:
- Integrating thermally conductive gap pads.
- Designing custom aluminum or copper heat sinks.
- Optimizing the cell spacing and layout for natural convection.
- Working with your mechanical team to advise on proper ventilation in your device’s enclosure.
Integrated Thermal Management Techniques
5. Can you describe your root cause analysis process for a field failure?
Even the best-designed products can fail. A supplier’s R&D depth is truly revealed not when things go right, but when they go wrong. How do they analyze and learn from a failure?
The Red Flag: "Just Send Us a New One"
A weak supplier will simply offer to replace a faulty unit. They have no interest or capability in finding the root cause, which means the problem is doomed to repeat itself.
The Green Flag: A Formal, Data-Driven Process
A strong R&D partner will see a field failure as a valuable learning opportunity. Ask: “What is your formal process for failure analysis?” A mature company will have a structured methodology like the 8D (Eight Disciplines) problem-solving process. They will be able to show you (non-confidential) examples of detailed failure analysis reports, which should include:
- Electrical testing data from the returned unit.
- A physical teardown and inspection (often with microscopic analysis).
- A data-driven hypothesis on the root cause.
- A corrective action plan to prevent the issue from recurring in future production.
This capability is your insurance policy that your supplier is committed to continuous improvement.
6. How do you engineer a pack to meet a specific cycle life target?
Cycle life is a critical driver of your product’s long-term ROI. A supplier who can only quote a generic number from a cell datasheet does not have the R&D depth to engineer for longevity.
Beyond the Datasheet: A Systems-Level Approach
Ask: “If we need our battery to last for at least 800 cycles in our specific application, how would you design for that?” A deep R&D team will discuss a multi-faceted strategy:
- Cell Chemistry Selection: They may recommend a specific NMC chemistry blend that is known for its stability.
- Conservative BMS Tuning: They will suggest setting the charge cut-off voltage slightly lower (e.g., 4.15V) and the discharge cut-off slightly higher (e.g., 3.1V) to keep the cells operating in their “comfort zone.”
- Thermal Management: They will emphasize how a cooler operating temperature directly translates to a longer cycle life.
- DoD Analysis: They may even suggest using a slightly higher capacity pack so that the typical Depth of Discharge (DoD) is lower, which exponentially increases cycle life.
7. What simulation and modeling tools do you use in your R&D process?
The most advanced R&D teams live in the digital world before they ever touch a physical component. Their use of simulation software is a direct measure of their sophistication and efficiency.
The Power of "Digital Prototyping"
Ask: “What role does simulation play in your design process?” A cutting-edge partner will describe a “digital prototyping” workflow:
- Mechanical Modeling (CAD): Designing the pack in 3D CAD software (like SolidWorks or CATIA).
- Structural Simulation (FEA): Using Finite Element Analysis to simulate the pack’s response to vibration, shock, and impact.
- Thermal Simulation: As mentioned, modeling the heat flow under various load conditions.
- Electrical Simulation (SPICE): Modeling the behavior of the BMS circuit before the PCB is ever fabricated.
The R&D Simulation Feedback Loop
This simulation-driven approach allows us to identify and fix potential problems at the cheapest and fastest stage—on the computer. It dramatically reduces the number of physical prototype iterations and shortens the overall development timeline.
8. What is your process for new material qualification and selection?
Battery technology is constantly evolving. The anode, cathode, and electrolyte materials are in a state of continuous improvement. A supplier with strong R&D is not just a user of these materials; they are an expert evaluator and integrator of them.
A Disciplined Approach to New Technology
Ask: “How do you evaluate and qualify a new cell chemistry or a new separator material?” An R&D-focused company will have a formal, multi-stage qualification process. At Hanery, this involves:
- Supplier Audit and Data Review: We start with a deep dive into the new material supplier’s own data and quality systems.
- Cell-Level Validation: We create a number of test cells in our R&D lab using the new material.
- Extensive Reliability Testing: These test cells are then subjected to months of extended cycle life testing, performance testing at extreme temperatures, and abuse testing to fully characterize their behavior and long-term stability.
Only after a new material has passed this exhaustive internal validation will we consider offering it to our OEM partners.
9. Can you walk me through your New Product Introduction (NPI) process?
A great idea is useless without a structured process to bring it to life. A supplier’s NPI process is the roadmap they follow to take a custom design from concept to reliable, high-volume production.
A Professional NPI Phase-Gate Process
A supplier who can present a clear, documented NPI process, like the APQP (Advanced Product Quality Planning) model used in the automotive industry, is a supplier who understands how to manage complex projects professionally.
10. How does your R&D team collaborate with manufacturing on DFM?
A design that is brilliant on paper but cannot be manufactured consistently at scale is a failure. There must be a strong, collaborative link between the R&D team and the manufacturing engineering team. Ask: “How and when does manufacturing get involved in your R&D process?” In a well-run organization, the answer should be “from day one.” Our DFM (Design for Manufacturability) process is a concurrent engineering effort where manufacturing engineers review the design at every stage to ensure it is optimized for our production lines.
11. What is your R&D approach to enabling safe, fast charging?
For many industrial applications, fast charging is a key requirement for maximizing uptime. However, it is also a major source of stress on the battery. A supplier’s R&D approach to this challenge is very revealing. A sophisticated partner will discuss a systems-level solution that involves cell selection, thermal management, and a smart BMS that can execute a multi-stage charging algorithm to pump in current quickly without causing long-term damage.
12. How do you design for performance in extreme temperatures?
A datasheet spec is always at room temperature. A strong R&D team can engineer for the real world. Ask: “What are our options if we need to guarantee performance at -20°C?” An R&D-driven supplier will discuss a range of potential solutions, from sourcing special low-temperature electrolyte cells to integrating a BMS-controlled internal heating element.
13. What is your process for system-level integration support?
The battery does not exist in a vacuum; it is part of your larger product ecosystem. A supplier whose R&D stops at the battery’s terminals is not a true partner. Ask: “What level of support can you provide to our team as we integrate the battery into our device?” A partner with deep R&D will have application engineers who can help your team with:
- Interpreting the battery’s communication protocol data.
- Troubleshooting system-level power management issues.
- Advising on the design of your product’s charging circuit.
14. What does your design validation testing (DVT) plan involve for a new custom pack?
Before a new design is released to production, it must be subjected to a brutal battery of tests to ensure it is reliable and safe. This is the Design Validation Testing (DVT) phase. Ask a supplier to provide you with a sample DVT plan. It should be a comprehensive document that includes not just basic performance tests, but also environmental tests (temperature and humidity cycling), mechanical tests (vibration and drop), and a full suite of abuse and safety tests.
15. How do you stay current with emerging battery technologies?
Finally, a true R&D partner is not just focused on today’s technology; they are your window into the future. Ask them: “What is on your technology roadmap? What are you investigating for our ‘Gen 2’ product?” A forward-looking R&D team will be able to discuss their research into next-generation technologies like silicon anodes, solid-state electrolytes, or new BMS components that will enable even higher performance in the years to come. This demonstrates that they are not just a supplier, but a long-term technology partner.
Frequently Asked Questions
What is a DFMEA and why is it an R&D tool?
A DFMEA (Design Failure Mode and Effects Analysis) is a structured, proactive R&D process used to identify potential design weaknesses before they become a problem. It’s a key part of the ISO 14971 risk management standard for medical devices⁶ and a best practice for any high-reliability product. A supplier with a strong R&D culture will use DFMEAs as a standard part of their design process.
Does a strong R&D capability mean a higher price?
It can mean a higher initial unit price, but it almost always leads to a lower Total Cost of Ownership (TCO). The R&D investment pays for itself through better performance, longer cycle life, higher reliability, and a faster time-to-market.
I’m not a battery expert. How can I effectively assess their technical answers?
You don’t need to be an expert. Listen for the quality of the answer. Are they specific? Do they talk about their “process”? Do they use data and examples? Or are their answers vague and high-level? A deep R&D team can explain complex topics in a clear, logical way.
What’s the difference between R&D and a standard engineering department?
A standard engineering department is often focused on sustaining current production (a “sustaining engineering” role). An R&D (Research and Development) department is forward-looking. They are focused on creating new designs, validating new technologies, and solving novel engineering challenges.
What are NRE costs and how do they relate to R&D?
NRE (Non-Recurring Engineering) costs are the one-time fees for the R&D work required for a custom project. This can include tooling for a custom cell, firmware development for a smart BMS, or specific certification testing. It’s a direct investment in the supplier’s R&D resources.
How much of a supplier’s revenue should be invested in R&D?
While it varies by industry, a technology-focused company will typically reinvest anywhere from 5% to 15% of its annual revenue back into R&D. You can ask a potential supplier about their R&D budget as a percentage of sales.
What is APQP?
APQP stands for Advanced Product Quality Planning. It’s a structured product development framework that originated in the automotive industry. A supplier who uses an APQP-based NPI process is demonstrating a very high level of process maturity.
Can I own the IP for a custom design created by my supplier’s R&D team?
Yes. This should be clearly defined in your supply agreement. Typically, for a design created exclusively for your project and funded by your NRE, you will own the intellectual property.
Should the R&D team be located in the same facility as the manufacturing?
This is highly advantageous. A co-located R&D and manufacturing team allows for a much tighter collaboration on DFM (Design for Manufacturability) and faster resolution of any production issues that arise during a new product launch.
How can a supplier’s R&D depth help me get my product to market faster?
It seems counterintuitive, but a strong R&D process accelerates your timeline. By using simulation to reduce physical prototypes, by providing deep integration support, and by proactively managing the certification process, a great R&D partner can shave months off your development schedule.
Conclusion: R&D Depth is the Ultimate Measure of a True Partner
In the end, the search for a Li-Po battery supplier is a search for competence. A supplier’s R&D capability is the ultimate, holistic measure of that competence. It is the engine that drives their ability to innovate, to solve hard problems, to ensure safety, and to build a product that will not just meet a specification but will delight your customers.
Answering these 15 questions will give you a high-resolution picture of a potential supplier’s true technical prowess. It will allow you to confidently distinguish the assemblers from the innovators, the order-takers from the problem-solvers. Choosing a partner with deep R&D is an investment in your own product’s future. It is a decision to compete not just on price, but on performance, reliability, and innovation.
If you believe your product deserves more than just an off-the-shelf solution, and you are looking for a partner who can answer these questions with confidence and clarity, we invite you to put our R&D team to the test. Let’s start a technical dialogue today. Schedule a Deep-Dive R&D Consultation with Our Engineers.
Reference
- CAN in Automation (CiA). (Reference for the CAN bus communication protocol).
- Texas Instruments. “Impedance Track™ Technology for Battery Fuel Gauges.” (Reference for a specific fuel gauging algorithm).
- American Society for Quality (ASQ). “What is 8D (Eight Disciplines)?”
- H. Berg, et al. “Aging mechanisms in Li-ion batteries.” Journal of Power Sources, 2014. (Reference on the impact of temperature on cycle life).
- Automotive Industry Action Group (AIAG). “Advanced Product Quality Planning (APQP) & Control Plan.”
- International Organization for Standardization. “ISO 14971:2019 – Medical devices — Application of risk management to medical devices.”
- Ansys, Inc. (Example of a major FEA and simulation software provider).
- International Electrotechnical Commission. “IEC 62133-2:2017 – Safety requirements for portable sealed secondary cells.”
- J. B. Goodenough, K. S. Park. “The Li-Ion Rechargeable Battery: A Perspective.” Journal of the American Chemical Society, 2013.
- M. G. Pecht. “A reliability perspective on the state-of-the-art of lithium-ion batteries.” IEEE Access, 2017.
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31/03/2026 Article pulished.
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