Manufacturing Improvements for DLA Lithium Batteries

The standardized, modular concept developed by TAF will be implemented for the BB-2590 under the proposed Phase II effort. Phase I prototyped the technology using PRC-148/152 battery packs.   TAF’s technology allows the cells of the battery pack to be separated from the military-specific cases. This creates a shelf-stable case and dramatic increases in surge capability. Using COTS 18650 cells decreases pack lifecycle cost, speeds fielding new cell technology, and adds new capabilities.   The BB-2590 is used in a variety of military applications. A full development cycle and engineering test process will be conducted to start low-rate initial production of a BB-2590, based on TAF’s technology, ready for FAT. The substantial sustainment savings will readily result in positive ROI in 3-5 years while providing additional supply chain benefits. TAF’s existing modular battery technology is at TRL4 with prototypes fabricated and tested in a laboratory environment. This effort will advance the technology in the BB-2590 to TRL 6 (Threshold), TRL 7 (Objective) to the point that the battery packs can be procured by DLA under a contract.    This technology is a leap forward in battery manufacturing, allowing Defense Logistics Agency (DLA) to deliver significant cost reductions for its battery acquisition program.