Battery-Powered Equipment Component Manufacturing
The shift to battery-powered lawn equipment is accelerating across every outdoor power equipment segment. For OEMs leading that transition — from cordless mowers and battery-electric zero-turns to handheld trimmers and compact utility platforms — the challenge extends well beyond cell chemistry and battery management systems. Every battery pack requires structural, stamped, welded, and finished mechanical components engineered for durability and manufactured at a production scale. Typically, metal components are used to connect the battery cells and transmit power to the machine. Regardless of the type of material (Copper, Aluminum, Nickel Plate, or Tin-Plated), we can provide a solution for you.
CS Cosmos STIHL is not a battery integrator or electronics supplier. We are a precision manufacturer of the mechanical battery pack components and metalformed assemblies that OEMs need to build production-ready battery-powered outdoor equipment.
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More than 50 years of OPE manufacturing expertise backs every part we produce. Since 1972, we have taken components from initial design concept through prototype validation, pilot production, and full-volume manufacturing for the outdoor power equipment industry. Our experience across hundreds of OPE component programs reflects the depth of Tier 1 supplier capability that enterprise OEM procurement teams expect.
OEM Component Manufacturing for Battery-Powered Lawn and Outdoor Equipment
Battery-powered platforms span a wide and growing range of equipment types. Cordless push mowers, battery-electric zero-turn platforms, handheld blowers, trimmers, chainsaws, backpack sprayers, and compact utility equipment each present distinct packaging, structural, and environmental challenges for the components that house and protect their battery systems.
Our role in this supply chain is focused and clearly defined: we manufacture the stamped, formed, welded, and finished mechanical components that surround, protect, and connect cells to transmit power to the machine.
We do not produce cells, BMS electronics, or charging systems. Instead, we partner with OEMs and their battery integrators to deliver the structural and mechanical battery pack components that complete the assembly — manufactured to the dimensional precision and repeatability that OEM qualification processes require. American-engineered and American-made.
Battery-Powered Equipment Platforms We Support
Our capabilities cover mechanical component needs across the full spectrum of electrified OPE platforms:
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Battery-powered mowers and zero-turns: Robust battery enclosures, structural trays, and vibration-resistant mounting systems engineered for continuous outdoor duty on commercial and residential platforms.
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Handheld and backpack battery tools: Lightweight stamped housings, compact enclosures, and formed structural components where every gram matters. These platforms demand tight weight tolerances, high cosmetic quality, and compact packaging — all produced at the volumes that leading handheld OEMs require.
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Compact utility and light equipment: Chassis-integrated components adapted to accommodate new battery pack geometries during gas-to-electric platform transitions.
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Emerging electrified platforms: Next-generation battery-electric products across OPE and adjacent light equipment categories where OEMs are building first-generation electrified product lines.
Battery Pack Components for Outdoor Power Equipment
A battery pack is more than cells and electronics. The structural and mechanical components that form the battery pack’s physical architecture are critical to safety, durability, and manufacturability.
Each component serves a specific function. Stamped trays provide the structural foundation. Formed enclosures and housings protect cells from impact, moisture, and debris. Brackets and retainers secure internal modules against vibration and shock. Every part must meet the dimensional consistency and material integrity that battery system performance demands.
Structural & Mechanical Battery Pack Components
We manufacture the stamped frames, trays, and internal support structures that form the backbone of OEM battery packs. These components bear static and dynamic loads during operation — continuous vibration from motors and cutting decks, impact shock from terrain, and the dead weight of cell modules.
Vibration isolation is addressed at the design stage. Reinforcement brackets, retainers, and structural supports maintain cell module alignment and prevent internal movement. Material selection, geometry, and mounting strategy are optimized for each platform’s specific shock and vibration profile based on our experience across hundreds of OPE component programs.
Electrical Support Components
Mechanical components support electrical connections, whether or not they are electrical devices. Terminal plugs, contact supports, and connector housings provide the physical structure that positions and retains electrical interfaces within the pack.
Isolation and retention are engineered for long-term reliability. Clearance features maintain the required spacing between conductive elements. Alignment components ensure connections remain secure under sustained vibration and thermal cycling in demanding outdoor environments.
Metal Stamping and Assembly for Battery Applications
Scalable manufacturing depends on precision-stamped parts delivered at OEM volumes. CS Cosmos STIHL’s stamping and assembly operations are purpose-built for high-volume, tight-tolerance, multi-operation manufacturing where dimensional control and process discipline are non-negotiable.
Our role differs from that of battery integrators. Cell selection, BMS design, and pack-level electrical assembly are their domain. Precision-stamped housings, welded structural subassemblies, and finished mechanical components are ours. This clear delineation allows OEMs to source the right expertise for each aspect of the battery system.
Stamped Components for Battery Housings & Enclosures
Progressive and precision stamping operations produce housings, enclosure panels, tray components, and structural elements. Material selection balances strength, weight, and corrosion resistance. Steel, stainless steel, and copper alloys are specified based on each program’s performance and cost targets.
Repeatability is engineered in from the start. Tooling is validated for the dimensional consistency required across high-volume OEM programs. Every stamped component meets assembly-line fit requirements, lot after lot, season after season — verified through in-process inspection at each manufacturing stage.
Welded & Assembled Battery Subsystems
Spot welding and MIG welding produce multi-part subassemblies. Integrated brackets, frames, and mounting assemblies are delivered weld-complete and ready for the OEM’s battery pack assembly process.
Assembly-ready delivery reduces line-side complexity. Components are kitted and packaged to support direct integration into production workflows, whether the OEM assembles battery packs in-house or works with a third-party integrator. This approach reduces inbound handling, incoming inspection burden, and staging time.
Engineering Support
Electrification introduces mechanical design challenges that differ from gas-powered platforms. Battery packs create new weight distributions, packaging constraints, and structural requirements that ripple through the entire equipment chassis.
Our engineering team collaborates with OEM design and product groups across the full development lifecycle. From initial concept review through prototyping, pilot production, and volume manufacturing, we provide design-for-manufacture expertise focused specifically on the stamped and assembled components within the battery system’s mechanical architecture — drawing on more than five decades of OPE component experience.
Deep Drawn Components for Exhaust & Structural Applications
Tolerance management and stack-up control directly affect cell module fit. Dimensional precision across multi-part assemblies determines whether electrical interfaces align correctly and maintain contact integrity throughout the product’s service life.
Weight reduction targets the inherent penalty of battery systems. Material optimization and geometry refinement offset added weight without compromising structural performance. Assembly simplification — consolidating parts, reducing weld operations, and designing for automated handling — lowers both per-unit cost and production line complexity.
Supporting OEM Transitions From Gas to Battery Power
Many OEMs manage simultaneous gas and battery product lines on shared chassis platforms. CS Cosmos STIHL supports this transition by engineering components for electrified platforms that integrate with existing chassis architectures, minimizing tooling investment and validation timelines.
Drop-in replacement strategies reduce transition risk. For entirely new battery-electric designs, our engineering team provides manufacturability feedback and prototyping support from concept through production launch — applying the same DFM discipline and process rigor we bring to our established gas-platform programs.
Durability, Safety, & Environmental Requirements
Choosing a component supplier is a commitment that extends across the full product lifecycle. CS Cosmos STIHL’s engineering Outdoor power equipment demands more from battery pack components than indoor or controlled-environment applications. Mechanical integrity under sustained vibration, thermal exposure from both the environment and the cells, and constant contact with moisture, debris, and corrosive agents define the performance envelope.team works alongside OEM design and procurement groups from initial concept review through prototyping, pilot production, full-volume manufacturing, and ongoing continuous improvement.
Our collaboration model is built for enterprise OEM expectations. Design-for-manufacture reviews, prototyping, manufacturability feedback, and validation support are standard. The goal is to identify cost, weight, and performance optimization opportunities before tooling is committed — not after.
Vibration, Thermal, & Environmental Exposure
Continuous vibration from motors, cutting systems, and terrain impact defines the operating baseline. Vibration isolation starts with component design: material selection, geometry, and fastening strategy are specified to manage transmitted loads and prevent fatigue failures.
​Thermal management addresses dual heat sources. Ambient heat during outdoor operation combines with radiated heat from cells during charge and discharge cycles. Moisture, grass debris, dust, and chemical exposure from fertilizers and treatments require finish specifications that provide long-term corrosion protection.
Safety Considerations for Mechanical Battery Components
Structural components contribute directly to system safety. Enclosures and housings provide impact protection and containment in the event of a cell failure. Retention systems and secure mounting prevent pack movement that could damage cells or compromise electrical connections.
We manufacture to the specifications defined by OEM safety requirements. CS Cosmos STIHL supports the testing and compliance processes that govern battery-powered equipment certification, providing the documentation, dimensional validation data, and process records that quality and compliance teams require during the approval process.
Manufacturing Scale and Quality Systems for Battery Component Programs
OEM procurement and quality teams apply rigorous qualification criteria to battery component suppliers. Production scalability, process repeatability, traceability, and documentation must meet the standards established for safety-critical component supply. CS Cosmos STIHL’s infrastructure and quality systems are built to meet those requirements across single- and multi-platform programs.
Production Scalability for Electrified Equipment
New battery-powered product lines often follow aggressive ramp schedules. Our capacity planning and program management approach supports pilot-to-full-volume timelines while maintaining quality and delivery performance.
Seasonal demand planning is a core competency. Developed through decades of serving the lawn and outdoor equipment market, our production scheduling ensures capacity is available when seasonal schedules peak and scales appropriately during off-season periods.
Quality Control & Traceability
Documented inspection and validation processes include in-line and end-of-line checkpoints. Statistical process monitoring is applied to critical dimensions and features across every production run.
Documentation packages support OEM qualification and compliance requirements. Deliverables include dimensional reports, material certifications, process validation records, and traceability data that align with PPAP-level expectations — providing the transparency and accountability that procurement and quality teams expect from safety-critical component suppliers.
Common Battery-Powered Equipment Use Cases
The following applications represent our primary battery component work. Each reflects a specific set of structural, environmental, and production requirements shaped by the equipment’s intended use and the OEM’s target market.
Battery-Powered Lawn Equipment
Cordless push mowers, riding mowers, and battery-electric zero-turn machines require structural battery pack components engineered for weight, vibration, and outdoor exposure. Stamped trays, formed enclosures, and welded mounting assemblies protect the battery system while integrating cleanly with the mower chassis. Endurance under continuous vibration and thermal cycling defines durability requirements.
Battery-Powered Outdoor Equipment
Handheld trimmers, blowers, chainsaws, and compact utility platforms place a premium on lightweight construction and compact packaging. Stamped housings and formed enclosures minimize weight without sacrificing impact protection. Battery pack components for handheld platforms must meet tight dimensional tolerances in small packaging envelopes where operator ergonomics, product weight, and cosmetic quality all affect market competitiveness.
Materials & Thickness Ranges
Steel, stainless steel, and HSLA grades are selected based on each application’s structural, weight, and corrosion resistance requirements. Cold-rolled steel provides formability and strength for trays and enclosures. Stainless steel is specified where corrosion exposure or cosmetic requirements demand higher performance. Various grades of copper and copper alloys for high-performance platines (Tin, Nickel, etc.) to reach the best electrical conductivity and corrosion resistance.
Thickness is optimized during DFM. Achieving target strength while minimizing weight is critical for battery-powered lawn equipment and handheld platforms where total product weight directly affects usability.
Request a Quote From CS Cosmos STIHL
Developing battery pack components for a new or existing platform? Whether you need stamped housings for a zero-turn battery system, lightweight enclosures for a handheld tool platform, or welded structural subassemblies for a new electrification program, CS Cosmos STIHL brings more than 50 years of OPE manufacturing expertise, 9M+ annual unit capacity, and ISO-aligned quality systems to support your program from initial concept through full production.
Contact our engineering and program management team to start the conversation.