Energy Storage System Assembly
and Battery Returns Support
Lotus is a US energy storage system assembler in Canton, Michigan. We build BMS controller boxes, integrate pre-welded modules into packs, and test assemblies to your specifications. Warehousing, Class 9 logistics, and depot repair are available from the same facility.
Plan the Build and the Return Process Together
An energy storage program needs a defined assembly process and a route for units that come back from the field. We work with your team to establish the build, test, handling, and service requirements.
Receiving and Assessing Returns
Returned packs need an agreed intake and diagnostic process. Share the product details, expected return volumes, and repair requirements so we can assess the handling and service work.
Coordinating the Assembly
Modules, controllers, harnesses, busbars, thermal components, and enclosures must come together to your design. We review the components, assembly instructions, and test requirements with your team.
Qualifying a US Production Partner
If your program needs US assembly, bring us the supplier requirements and documentation you need. We can review the work to be performed in Canton and the production records required for your program.
An Energy Storage System Assembler
Working to Your Design
Lotus works with energy storage OEMs, system integrators, and BMS designers on the physical build. Our scope includes controller box build, harness and busbar assembly, module-to-pack integration, enclosure assembly, and testing.
We receive pre-welded modules from your suppliers. Cell-to-module welding remains with the cell supplier or a specialist partner. Assembly and inspection follow your drawings and agreed acceptance criteria.
Our Canton facility holds ISO 9001:2015 and ISO 14001:2015 certification. Depot repair and reverse logistics can be included in the program alongside production.
- 4,000 A on-site charging capacity, supporting 1,000+ batteries simultaneously
- Class 9 hazmat handling at our Canton facility
- 12 truck wells for receiving and dispatch
- ISO 9001:2015 and ISO 14001:2015 certified
- Warehousing, depot repair, and return processing on site
From Incoming Components to Field Returns
Choose the services your ESS program needs. We review the scope, equipment requirements, and acceptance criteria before production begins.
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Incoming Inspection
Receive pre-welded modules, BMS boards, and structural components, with incoming checks to your specifications and Class 9 receiving procedures.
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BMS Controller Box Build
Integrate supplied controller boards, enclosures, connectors, cable harnesses, and busbars to your drawings. The work is box build and integration, not battery cell production.
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Pack Assembly & Integration
Integrate pre-welded modules with BMS controls, thermal management, harnesses, busbars, and enclosures or racks. Connections are torqued and documented to the build requirements. Cell-to-module welding remains with your supplier or specialist partner.
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Testing & Validation
Electrical testing, charge/discharge cycling, BMS checks, and thermal validation to your program specifications. Test results are recorded against the agreed acceptance criteria.
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Warehousing & Class 9 Logistics
Storage and Class 9 shipping for distribution and deployment. We agree packaging, handling, and dispatch requirements with your team.
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Reverse Logistics & Refurbishment
Class 9 intake, module-level diagnostics, repair, refurbishment, and end-of-life processing for agreed programs. Returned units are assessed to determine the appropriate next step.
Assembly and Logistics in Canton, Michigan
Our Canton facility brings production, storage, and service operations together. Your engineering team can visit to review the assembly process, inspect builds, and discuss changes with the people doing the work.
Warehousing and receiving and dispatch facilities support both outbound shipments and field returns. We plan these flows around your component deliveries, production schedule, and service requirements.
- Canton location in Metro Detroit
- Class 9 shipping and handling
- 12 truck wells for receiving and dispatch
- Production, warehousing, and depot repair at the same site
Sq. Ft. Facility
Sq. Ft. Cleanroom
Years Manufacturing
Industry Partners
Lotus has processed, recovered, and refurbished more than 250,000 e-mobility battery units, and brings 31 years of contract manufacturing experience to ESS assembly, with Class 9 handling, warehousing, and depot repair at the same Canton facility.
Assembly and service scopes are agreed for each energy storage program.
Battery Returns Support
Class 9 intake, module-level diagnostics, repair, and refurbishment can be included in your service program. We agree the return workflow and assessment criteria with your team.
Documented Quality Processes
Our facility holds ISO 9001:2015 and ISO 14001:2015 certification. Assembly, inspection, and test records follow the requirements agreed for your product.
Support for OEMs and Integrators
We work from your design and specifications on controller box build, harness and busbar assembly, pack integration, and depot repair. Your team retains ownership of the product design.
The Capabilities Behind This Program
Manufacturing & Assembly
Build-to-print and turnkey assembly, including controller box build and component integration.
See the capabilityCleanroom Operations
ISO Class 6 and Class 7 cleanroom space for component work that requires contamination control.
See the capability3PL Warehousing & Distribution
Storage, Class 9 handling, and dispatch to distribution channels or deployment sites.
See the capabilityEnergy Storage System Assembly FAQ
An energy storage system assembler integrates supplied modules, controllers, thermal components, wiring, and enclosures to the product design. Lotus supports module-to-pack assembly, BMS controller box build, testing, packaging, and service programs from Canton, Michigan.
Our assembly scope covers utility and grid-scale, commercial and industrial, and residential ESS programs. We work with OEMs, system integrators, and BMS designers, reviewing the product configuration, quantities, test requirements, and handling needs for each project.
No. We integrate pre-welded modules supplied by your cell supplier or a specialist partner. Our work begins with module receiving and includes pack integration, BMS controller box build, harnesses, busbars, enclosures, and testing.
Yes. Lotus operates in Canton, Michigan, with assembly, testing, warehousing, and depot repair at the same facility. If your program has domestic-content or procurement requirements, share them during qualification so we can review the scope and supporting records. A US assembly location alone does not establish program eligibility.
Testing can include charge/discharge cycling, BMS functionality checks, insulation resistance, electrical testing, and thermal validation. We agree the procedures, equipment requirements, acceptance criteria, and test records with your team before the program begins.
Yes, for programs within the agreed scope. Services include Class 9 receiving, module-level diagnostics, repair, refurbishment, and end-of-life processing through R2-certified recycling partners. We review the product and return requirements with your team before setting up the intake process.
Yes. Our facility includes 20,000+ sq. ft. of ISO Class 6 and Class 7 cleanroom space. It is available for sensitive component assembly and integration when the process specification requires contamination control.
Send the system description, drawings, bill of materials, expected quantities, and target dates. Identify which components arrive assembled, the work you want Lotus to perform, and the test and handling requirements. Include expected return volumes if you also need depot support.
Planning your next program?
A few quick questions, about two minutes. We'll be in touch within one business day.