When it comes to powering off-grid adventures, Battle Born Batteries are trusted by RVers, boaters, adventurers, off-gridders, and energy enthusiasts around the world. But what makes these lithium batteries so reliable? It all starts with a thorough and detailed lithium battery manufacturing process—engineered and assembled right here in the USA.

Join Dragonfly Energy CEO Denis Phares for a behind-the-scenes tour of our 400,000-square-foot facility in Reno, Nevada, where innovation, quality control, and energy independence come together to build the most trusted lithium power systems on the market.

American Lithium Battery Manufacturing

At our Reno facility, we oversee every stage of the LiFePO4 battery production process. From cell selection to final quality checks, our mission is simple: deliver clean, efficient, and dependable lithium power for a wide range of applications, including lithium batteries for RVs, marine, solar, overland, industrial, and more.

We begin by loading Grade A lithium iron phosphate cells into battery modules. After a visual inspection for alignment and polarity, the modules are loaded into precision welding machines that spot weld current collectors to both the anode and cathode. This forms the basis of each battery’s energy storage capacity—whether 50Ah, 75Ah, 100Ah, or 270Ah.

Testing for Reliability and Performance

Once welded, each battery module goes through a full charge and discharge cycle using specialized equipment. This step:

• Verifies total capacity
• Ensures modules are balanced at 100% State of Charge
• Reduces performance variation within a pack

After cycling, modules are serialized, sorted, and staged for final battery assembly. This level of detail is crucial to ensuring our LiFePO4 batteries meet the high expectations of our customers—and our own 10-year warranty.

Assembling the Battle Born Battery

In final assembly, battery modules are combined in series (four for 12V systems, eight for 24V systems) and integrated with other components:

• Sensor wires for monitoring and diagnostics
• Other current carrying metals, like brass and copper
• Integrated heating technology systems for cold-weather performance in heated battery models
• Battery Management System (BMS) to control current flow and protect against over-voltage, over-temperature, and short-circuit conditions

Built-In Heating for Cold Weather Performance

When temperatures drop, Battle Born Batteries keep delivering with our heated battery models. Our integrated heating technology uses internal heating pads and control systems to safely warm the battery before charging in cold climates. Automatically activated below 35°F, this feature ensures optimal performance and battery protection with no external heating required. Whether you’re winter camping or living off-grid in the mountains, you can count on reliable lithium power even in freezing conditions.

Built-In Battery Management System (BMS)

Every Battle Born Battery is equipped with an internal battery management system (BMS), the brain behind our battery’s safety and performance. The BMS monitors voltage, current, and temperature to prevent overcharging, over-discharging, and overheating. It also ensures cell balancing and protects against short circuits. This technology allows for safe, efficient energy use and long-term reliability, making our LiFePO4 batteries some of the safest and most dependable on the market.

Built, Tested, and Sealed for Off Road, Rugged Adventures

At Battle Born Batteries, durability isn’t optional—it’s engineered into every battery we build. Before a single product leaves our Reno, Nevada manufacturing facility, it undergoes a rigorous, multi-stage quality assurance process to ensure it can handle whatever the road (or trail) throws at it.

Each battery is thoroughly tested for:

• Voltage cutoffs to prevent overcharging or deep discharging
• Current limits to handle high-power draws without damage
• Temperature thresholds to protect internal components in extreme climates
• Short-circuit protection for safe, dependable operation in real-world conditions

After passing these critical checks, every unit is epoxied and sealed to IP65 standards, meaning it’s protected against dust, water, and harsh environmental exposure. Whether it’s mounted in a bumpy overland rig, a marine vessel, or a backcountry cabin, our batteries are designed to perform in rugged, off-grid environments.

Each battery is then packaged to meet strict hazmat shipping regulations, ensuring safe transport across North America. From direct-to-consumer orders to dealer distribution and OEM integrations, our reliable lithium battery systems arrive ready to power your next adventure—no matter where the journey takes you.

More Than Batteries: Complete Lithium Power Systems

At Battle Born, we don’t just manufacture premium lithium batteries, we also engineer turnkey lithium power systems built to meet the demands of today’s most advanced energy applications. Inside our Reno facility, our team assembles fully integrated systems designed for seamless performance, scalability, and reliability in the field.

Based on the needs and application, custom systems can include:

• Battle Born LiFePO4 batteries for long-lasting, safe, and maintenance-free energy storage
• Smart chargers and solar charge controllers that optimize charging from shore, solar, or generator power
• Wakespeed alternator regulators to safely harness vehicle-based charging while on the move
• Rugged enclosures that are pre-wired, pre-configured, and ready for plug-and-play installation

These complete lithium battery solutions are built for OEM partners who demand dependable off-grid power—whether it’s for next-gen RVs, specialty vehicles, mobile medical units, or tactical and emergency command centers.

By designing, testing, and assembling everything in-house, we ensure each system is tailored to the customer’s specifications and field-ready upon delivery. And the result is a robust and integrated energy system that simplifies installation, reduces downtime, and delivers reliable lithium power when it matters most.

Powering a Renewable Future

At Battle Born Batteries, we’re not just building batteries—we’re powering a movement toward energy independence, sustainability, and smarter off-grid living. With every unit we ship, we reaffirm our commitment to:

• American assembly and manufacturing
• Advanced lithium battery technology
• Reliable energy storage for every adventure

Whether you’re heading off-grid or building the next generation of renewable energy systems, you can trust that your power was built right here in Reno, Nevada—with precision, passion, and purpose. Explore our full line of LiFePO4 batteries and energy storage systems and experience the difference of American lithium power.