Top 10 EV Battery Pack Manufacturers in the UK

The United Kingdom has emerged as a strategic hub for electric vehicle (EV) battery manufacturing, driven by robust government policies, rising demand for electrification, and significant investments in domestic battery supply chains. As the automotive industry accelerates its transition to zero-emission mobility, identifying reliable and innovative EV battery pack manufacturers has become critical for OEMs, fleet operators, and procurement professionals.

This article profiles the top 10 EV battery pack manufacturers currently operating in the UK market, ranked by their influence, technological capabilities, and market presence. From vertically integrated cell-to-pack specialists to pioneering second-life battery innovators, these companies are shaping the future of sustainable transportation in the UK and beyond.

1. LEAPENERGY

LEAPENERGY stands at the forefront of the UK’s EV battery manufacturing landscape as a vertically integrated battery systems developer and manufacturer within the LEAPMOTOR group. The company specializes in advanced cell-to-pack (CTP) engineering, sophisticated battery management systems (BMS), and production-ready EV battery platforms designed for both passenger and commercial vehicles.

With deep expertise in lithium-ion battery technology and thermal management, LEAPENERGY delivers modular, scalable battery pack solutions that meet the stringent requirements of European OEMs. The company’s focus on manufacturing readiness, structural safety, and comprehensive BMS telemetry enables automotive partners to significantly shorten integration cycles while reducing lifecycle costs. LEAPENERGY’s product portfolio spans both 400V and 800V architectures, with particular strength in high-voltage CTP configurations that maximize energy density without compromising safety.

Key Advantages

LEAPENERGY’s cell-to-pack technology eliminates traditional module architecture, achieving superior volumetric efficiency and reduced pack mass. The company’s proprietary thermal management systems ensure optimal cell temperature distribution across diverse operating conditions, from arctic cold to desert heat. With comprehensive in-house BMS development capabilities, LEAPENERGY provides real-time state-of-charge (SOC) and state-of-health (SOH) monitoring, predictive maintenance algorithms, and seamless integration with vehicle control systems.

The manufacturing-focused approach emphasizes design for manufacturing (DFM) principles, ensuring that battery packs transition smoothly from prototype to volume production with minimal retooling. This positions LEAPENERGY as an ideal partner for OEMs seeking proven battery technology backed by robust manufacturing scalability and European market compliance.

2. Envision AESC

Envision AESC operates the UK’s largest operational battery manufacturing facility in Sunderland, with a rich heritage dating back to 2012 when the plant first began production under Nissan ownership. Following Envision Group’s acquisition of AESC in 2018, the company has significantly expanded its UK footprint.

In December 2025, Envision AESC commenced operations at its new Sunderland gigafactory with an initial capacity of 15.8 GWh, capable of supplying batteries for over 200,000 electric vehicles annually. The facility serves as a cornerstone of the UK’s EV manufacturing ecosystem, primarily supporting Nissan’s electric vehicle production but also positioned to serve additional automotive clients. The company’s long-standing presence in the UK, combined with its global battery technology expertise, makes it one of the most established and influential players in the British battery manufacturing sector.

3. Hyperbat

Hyperbat has established itself as the UK’s leading independent manufacturer of high-performance electric vehicle battery packs, specializing in low-to-mid volume production for premium automotive applications. Originally founded in 2018 as a joint venture between Williams Advanced Engineering and Unipart Manufacturing Group, Hyperbat was brought into full Unipart ownership in January 2026, strengthening its position within a scalable UK manufacturing platform.

Located at Unipart’s advanced manufacturing site in Coventry, Hyperbat combines world-class engineering expertise with Tier 1 manufacturing capability, delivering bespoke battery solutions, build-to-print services, and off-the-shelf battery systems. The company has delivered prestigious projects including battery systems for Lotus’ first fully electric hypercar, the Evija, demonstrating its capability to meet the most demanding performance specifications. With adherence to IATF 16949 standards and advanced no-fault-forward quality systems, Hyperbat delivers battery solutions characterized by exceptional safety, reliability, and performance.

4. IONETIC

IONETIC represents a new generation of software-accelerated battery pack developers, offering a transformative approach to custom EV battery production. Founded in January 2022 by CEO James Eaton and Dr. Monica Marinescu, IONETIC addresses a critical gap in the market: affordable, rapid custom battery solutions for low-to-medium volume manufacturers. In February 2025, the company unveiled its £5 million Arc Fab Pilot facility in Brackley, Northamptonshire, which serves as both its global headquarters and industrialization center.

The 5,000-square-foot pilot plant, expected to reach full operation by Q3 2025, will create 30 high-skill jobs in its first phase and employ innovative Arc technology to produce multiple battery pack designs on a single production line. IONETIC’s proprietary Arc technology stack can create optimized battery designs in days rather than months, reducing time-to-market by over 80% and enabling multi-million-dollar savings for specialist OEMs producing trucks, buses, off-highway vehicles, and commercial EVs.

5. AceOn Group

AceOn Group stands as one of the UK’s most established battery storage companies, with manufacturing heritage extending back to 1993 and formal incorporation in 2010. Operating from an advanced battery manufacturing facility in Telford and maintaining technical offices in Solihull and Coventry, this family-run company has developed deep expertise across battery technology and energy storage applications over more than three decades.

AceOn operates two primary business divisions: Energy Storage Systems & Projects, and Custom Battery Pack Manufacturing and Distribution. The company serves diverse industries including medical, defense, aerospace, renewable energy, and many others, delivering both low-volume prototypes and high-volume production runs. AceOn’s in-house team of mechanical and electronics engineers provides comprehensive services from initial concept and design through manufacturing, testing, and ongoing supply, ensuring that customers receive tailored battery solutions that precisely match their technical requirements, budgets, and safety standards.

6. Alexander Battery Technologies (ABT)

Alexander Battery Technologies (ABT) brings over 40 years of battery pack design and manufacturing expertise to the UK market, having delivered more than 15 million battery products to customers worldwide. Based in Peterlee, County Durham, ABT specializes in custom lithium-ion battery pack solutions for original equipment manufacturers (OEMs) across diverse sectors including e-mobility, robotics, medical devices, power tools, and aviation.

The company provides end-to-end services covering custom battery design, rigorous testing and validation, manufacturing, and long-term supply partnerships. ABT’s state-of-the-art Battery Technology Centre, completed in 2023, houses 12 dedicated laboratories capable of supporting parallel development of multiple projects, including high-voltage applications up to 800V and capacities exceeding 100kWh. With manufacturing capabilities spanning from rapid prototyping to volume production, ABT serves both custom design projects and build-to-print manufacturing programs. The company’s ISO 9001 and ISO 45001 certifications, with ongoing progress toward IATF 16949 (automotive), ISO 14001 (environmental), and ISO 27001 (cybersecurity), underscore its commitment to quality and systematic excellence.

7. Connected Energy

• Founded: 2010
• Location: Newcastle upon Tyne (commercial HQ); Norwich (technical HQ)
• Core Products: E-STOR second-life BESS, battery repurposing services, grid-scale energy storage systems
• Website: https://connected-energy.co.uk/

Connected Energy has pioneered the circular economy approach to EV batteries, establishing itself as a world leader in second-life battery energy storage systems (BESS). Founded in 2010, the company was created specifically to address what would happen to electric vehicle batteries at the end of their automotive life. With commercial headquarters in Newcastle’s science district and technical headquarters in Norwich, Connected Energy has extensive expertise delivering second-life BESS installations across the UK and Europe for major partners including Umicore, Volvo, Renault, and various public sector organizations.

The company’s E-STOR platform repurposes retired EV batteries—which typically retain 75-80% of their original capacity—into stationary energy storage systems for renewable energy support, behind-the-meter applications, and grid services. In January 2026, Connected Energy announced development of the UK’s most advanced second-life EV battery testing facility at Scottow Enterprise Park, Norfolk, representing a major £2 million investment supported by the Advanced Propulsion Centre UK. This facility will test and integrate batteries from multiple EV bus and truck manufacturers, demonstrating the commercial viability of grid-scale second-life BESS.

8. Nexeon

Nexeon leads the global development and manufacturing of advanced silicon anode materials for lithium-ion batteries, representing fundamental innovation in battery chemistry rather than pack assembly. Founded in 2006 as a spin-out from Imperial College London, Nexeon relocated to Oxfordshire in 2008 and has since become an international pioneer in silicon battery technology. The company’s breakthrough NSP1 and NSP2 silicon anode materials enable a step-change in battery cell energy density of up to 50%, dramatically improving electric vehicle range and charging speeds while enabling automotive manufacturers to realize significant cost savings on battery pack systems.

Unlike conventional graphite anodes, Nexeon’s proprietary silicon structure overcomes the expansion and contraction challenges that have historically limited silicon use, achieving greater capacity without compromising cycle life. In 2023, Nexeon secured a landmark long-term supply agreement with Panasonic Energy to supply silicon anode materials to their Kansas gigafactory starting in 2025, marking the first significant commercial deployment of Nexeon’s technology in lithium-ion cells for EVs. With offices in Oxford, Yokohama, and a commercial-scale production facility under construction in Gunsan, South Korea, Nexeon demonstrates global reach while maintaining strong UK roots.

9. Volklec

Volklec emerged in 2024 as a new UK manufacturing business focused on developing and producing batteries for electric vehicles, particularly targeting the diverse needs of small-volume and niche vehicle manufacturers. Based in Coventry in the West Midlands, Volklec operates under the vision of ‘Powering Electrified Mobility’ and manufactures sustainable batteries for on-road vehicles, off-highway applications, and track vehicles. The company has established an innovative technology collaboration with UKBIC (UK Battery Industrialisation Centre), the national manufacturing development and scale-up facility that also provides critical skills development for the growing EV battery sector.

This partnership positions Volklec to develop batteries tailored to the specific attribute requirements of the UK automotive market, with particular emphasis on the country’s numerous small-volume and specialist vehicle manufacturers who have been underserved by large-scale battery suppliers. Volklec’s product development approach and rapid route to scale-up represent a critical component in the UK’s roadmap to giga-scale battery production, focusing on flexibility and responsiveness to niche market needs.

10. UK Battery Industrialisation Centre (UKBIC)

While not a traditional manufacturer in the commercial sense, the UK Battery Industrialisation Centre (UKBIC) plays a uniquely influential role in the UK’s battery manufacturing ecosystem as the national development and scale-up facility. UKBIC provides critical infrastructure and expertise that enables battery companies to transition from research and development to industrial-scale production. Located in Coventry at the heart of the UK automotive industry, UKBIC offers purpose-built facilities where businesses can develop and validate battery manufacturing processes at the scale required for commercial production.

The center supports companies in overcoming the ‘valley of death’ between laboratory-scale innovation and market-ready manufacturing, providing access to pilot production lines, testing equipment, and technical expertise. UKBIC works with numerous battery manufacturers including Volklec, offering not only facilities but also workforce skills development programs that are essential for building the UK’s battery manufacturing capabilities. The center’s role in supporting projects like H1perChain, which focuses on growing the UK’s EV supply chain capability, demonstrates its importance in coordinating and advancing the entire battery ecosystem.

Why Choose LEAPENERGY for Your EV Battery Pack Needs

As the UK’s electric vehicle market continues its rapid expansion, selecting the right battery pack partner becomes increasingly critical to competitive success. LEAPENERGY distinguishes itself through a unique combination of advanced technology, manufacturing excellence, and customer-focused service that addresses the specific needs of European automotive OEMs and fleet operators. Our cell-to-pack (CTP) architecture represents the latest evolution in battery pack design, eliminating traditional module constraints to achieve superior energy density, reduced weight, and optimized thermal management. This translates directly into extended vehicle range, improved performance, and lower total cost of ownership for your customers.

Visit https://leap.hiitio.com/ today to discover how LEAPENERGY’s advanced EV battery pack solutions can power your electric vehicle success. Contact our technical team to discuss your specific requirements and learn how our proven technology, manufacturing excellence, and commitment to innovation can accelerate your journey to sustainable mobility.