In the defence sector, a failing battery is not just inconvenient. It can compromise your mission and jeopardise your equipment and safety.
A rugged military battery must perform reliably under pressure, often in conditions far beyond those used in standard commercial settings. From extreme temperatures to electromagnetic interference, there are several critical risks that engineers need to design around from the outset.
At Lincad, we’ve spent decades developing battery systems for demanding defence and security applications. Below, we outline seven of the most common failure risks we see in the field, and how they can be addressed.
1. Extreme Temperatures
Military operations rarely happen in controlled environments. Batteries may be exposed to freezing Arctic conditions or intense desert heat. Both of these extremes can affect the performance, capacity and lifespan of batteries.
We design our battery systems to operate in a wide range of temperatures, using carefully selected chemistries and thermal management strategies to maintain a decent performance where standard batteries would fail.
2. Shocks and Vibrations
Whether mounted in a vehicle, deployed in the field, or used in airborne systems, batteries are often subjected to constant shocks and vibrations. Over time, this can damage internal components or lead to connections failing.
Our ruggedised battery designs are built to meet relevant MIL-STD and Def Stan requirements, ensuring structural integrity even in high-impact environments.
3. Water and Dust Ingress
Ingress from water or fine particles can quickly render a battery inoperable. This is especially critical for applications such as ROVs, surveillance systems, or field communications equipment.
We develop sealed and protected enclosures to meet appropriate IP ratings, ensuring our batteries remain operational in harsh and unpredictable conditions.
4. Electromagnetic Interference (EMI)
In defence systems, electromagnetic compatibility is essential. Batteries must not interfere with surrounding electronics, nor be affected by them.
We have extensive experience designing battery systems where EMC performance is critical, ensuring reliable operation alongside sensitive equipment such as ECM systems and communications devices.
5. Thermal Runaway and Safety Risks
Safety is a key concern, particularly with high-energy battery systems. Thermal runaway can lead to overheating, fire, or system failure if not properly managed. This is the dangerous chain reaction inside a battery where heat builds up faster than it can escape, causing the battery to get hotter and hotter until it fails.
Our designs incorporate robust battery management systems (BMS), protective circuitry, and proven engineering practices to minimise these risks and ensure safe operation.
6. Capacity Degradation Over Time
All batteries degrade, but in mission-critical applications, unexpected loss of capacity can cause serious issues. A poor design, unsuitable chemistry or use in harsh conditions can accelerate this process.
We work closely with our customers to match the right battery solution to the application, balancing energy density, cycle life and environmental resilience to maximise reliability over time.
7. Mismatch Between Application and Battery Design
One of the most common causes of failure is simply using the wrong battery for the job. Off-the-shelf solutions may not meet the specific demands of a defence application.
That’s why we offer both COTS products and bespoke battery design services. If a standard product does not fully meet requirements, we can modify or develop a tailored solution using proven building blocks to deliver the right performance.
Designing for Reliability from the Start
Avoiding a battery failing in the field starts with the right decisions over the design early in the process. Engineers must consider not just performance specifications, but the full operating environment and lifecycle of the system.
At Lincad, we take a collaborative approach. Whether it’s powering a handheld radio, supporting electronic counter measures, or enabling propulsion for remotely operated vehicles, we design and manufacture battery systems that are built to perform in the most demanding conditions.
If you are specifying a rugged military battery for a new or existing project, taking the time to address these risks upfront can make the difference between the success and failure of a mission.