How a Growing EV Battery Company Fast-Tracked Their Product Launch with Karkhana.io
Rising energy storage company set out to build a high-performance lithium-ion battery pack for electric two-wheelers
Overview
When a rising energy storage company set out to build a high-performance lithium-ion battery pack for electric two-wheelers, they knew the road from prototype to production would be anything but simple. Their core strength was crystal clear: designing robust and reliable battery solutions tailored for the growing EV market in India.
But designing a battery and building it at scale are two very different challenges.
As they prepared to transition from product development to manufacturing, the team faced a critical question: How do we take a highly engineered design and turn it into a scalable, manufacturable product, without compromising on performance or timelines?
That’s where Karkhana.io came in.
Project at a Glance
Industry:
Electric Vehicles & Energy Storage
Product:
High-performance lithium-ion battery pack for electric two-wheelers
Services Offered
Rapid prototyping, Design for Manufacturing (DFM) support, complete box-build manufacturing, end-to-end sourcing, scalable production setup
Capabilities Leveraged
Rapid prototyping, zero-defect manufacturing, design optimization, multi-category sourcing, scalable production.
Core Customer Challenges
Upliance needed a manufacturing partner who could take full ownership of the product journey:
Component sourcing
Box-build manufacturing
DFM guidance
Rapid prototyping
Primary Execution Priorities
This energy-tech company had a powerful vision: to build high-quality battery packs that could accelerate India’s EV transformation. Their engineering team was ready with product designs, but they faced several execution challenges:
- Sourcing a wide range of components, from mechanical enclosures to electrical parts.
- Finding a reliable partner for complete box-build manufacturing.
- Rapid prototyping support with a clear path to scale up production.
- Guidance on Design for Manufacturing (DFM) to ensure designs can be efficiently built at scale.
They didn’t just want a vendor. They needed a partner who could offer speed, flexibility, and deep manufacturing expertise
What did we do?
Karkhana.io partnered closely with the company from the earliest stages of production planning, bridging the gap between design and manufacturing. We delivered a fully functional prototype in just four weeks, enabling immediate testing and validation. Our team provided in-depth Design for Manufacturing (DFM) guidance to optimize the product for large-scale production without compromising performance.
We also managed end-to-end sourcing, covering mechanical enclosures, plastic parts, PCBs, wiring, fasteners, and thermal materials—ensuring all components met stringent quality standards. The complete box-build manufacturing process was set up with scalability in mind, allowing smooth progression from pilot runs to mass production.
Phase 1: SKD Import & Initial Assembly Setup
Timeframe: ~ 4 Weeks
Localization: ~ 20%
We began by importing over 30 components from China, including plastics, jars, harnesses, and accessories, while localizing core operations like assembly, painting, packaging, and hardware integration.
Key wins:
- Identified local suppliers for PCBA and tablets
- Established a lean assembly line with standard tools and station-wise processes
- Managed end-to-end procurement and BIS certifications
- Delivered a 100% increase in throughput from Day 1
Phase 2: Component Localization & Process Optimization
Timeframe: ~ 8-10 weeks
Localization: ~ 30-40%
Next, we dove deep into each imported component to evaluate its potential for localization based on cost, volume, and technical feasibility.
What we did:
- Identified and onboarded local vendors for critical electrical parts (PCBA, control boards, harnesses)
- Transitioned 3D-printed parts to full tooling (mould design, material selection)
- Replaced off-the-shelf tablets with custom solutions (including BIS-certified assembly in India)
- Developed process flows for IQC, in-line testing, and PDI to standardize quality control
Phase 3: Scaling Plastics & Accessory Localization
Timeframe: ~ 10-14 weeks
Localization: ~ 70-80%
With the core electronics localized, we moved on to plastics and accessories.
Our focus:
- Expanded vendor network to include high-quality plastics and localized accessories
- Modified the assembly workflow to accommodate more localized SKUs without disrupting product performance
- Conducted functional validation and stress testing to ensure product premiumness
Phase 4: Production Ramp-Up & Final Optimization
Timeframe: ~ 16 weeks
Localization: ~ 80%+
This phase marked the transition from prototype to pilot to full production scale.
Key wins:
- Real-time production monitoring and performance tracking
- AOI (Automated Optical Inspection), functional testing, and reliability checks on every unit
- Design and implementation of new packaging (transitioning from PP to cardboard for cost and quality gains)
- Localization of all branding elements—stickers, manuals, decals—to meet both brand and compliance standards
Key Outcome
From batch 1 to batch 5, we optimized sourcing and processes to bring down per-unit costs significantly.
In just 6 months, we scaled production from 1,000 to 3,000 units/month, without sacrificing quality.
Seamless transition from EVT to PVT with on-time market launch
More vendor options meant more resilience and flexibility for future product iterations
First working prototype delivered in 4 weeks
Zero manufacturing defects during 2 months of testing
Seamless transition from EVT to PVT with on-time market launch
Outcome Overview
The collaboration enabled the client to move from engineering validation to market-ready production on schedule, with zero defects reported during testing. By streamlining sourcing, design optimization, and manufacturing setup under one roof, Karkhana.io helped the company accelerate market entry while maintaining uncompromising quality and flexibility for future scaling.
Testimonials
Frequently Asked Questions
Overview
The collaboration enabled the client to move from engineering validation to market-ready production on schedule, with zero defects reported during testing. By streamlining sourcing, design optimization, and manufacturing setup under one roof, Karkhana.io helped the company accelerate market entry while maintaining uncompromising quality and flexibility for future scaling.
Overview
The collaboration enabled the client to move from engineering validation to market-ready production on schedule, with zero defects reported during testing. By streamlining sourcing, design optimization, and manufacturing setup under one roof, Karkhana.io helped the company accelerate market entry while maintaining uncompromising quality and flexibility for future scaling.
Overview
The collaboration enabled the client to move from engineering validation to market-ready production on schedule, with zero defects reported during testing. By streamlining sourcing, design optimization, and manufacturing setup under one roof, Karkhana.io helped the company accelerate market entry while maintaining uncompromising quality and flexibility for future scaling.
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