Thermal batteries are reserve energy sources that remain inert until activated, making them ideal for defense systems requiring long shelf life, instant readiness, and reliable power under extreme conditions. Designed for high shock, vibration, and temperature environments, thermal batteries play a critical role in modern guided munitions, missiles, and smart subsystems.
Missile & Cruise Systems
Sustaining long-range and high-G operations in air-to-air, air-to-ground, and sea-launched configurations.
Smart Munitions
Including guidance kits, dual-mode fuzes, and programmable detonation mechanisms.
Tactical Artillery & Rockets
Delivering reliable power for on-board electronics and fuzing under high acceleration and spin.
Naval and Underwater Systems
Used in torpedoes, smart mines, and underwater countermeasures requiring reliable operation under hydrostatic pressure.
Emergency & Auxiliary Systems
Ejection seats, decoy dispensers, and backup telemetry systems for aviation and missile defense.
At PILTEK, we offer a full range of thermal battery solutions tailored to your platform’s requirements—combining advanced electrochemical modeling, flexible activation mechanisms, and MIL-STD-810H environmental compliance. Our ITAR-free technologies support domestic and allied defense ecosystems worldwide.
Thermal Battery Types (by Form Factor and Application)
1. Standard Disc-Stack Batteries
The most common configuration—stacked electrochemical cells with solid-state electrolytes. Used in guided bombs, missiles, and rocket systems.
2. Conformal Batteries
Designed with customized geometries (e.g., oval or rectangular) to fit within restricted or irregular enclosures. Often used in air-launched munitions and UAV payloads.
3. Miniature Thermal Batteries
Ultra-compact cells developed for space-constrained systems such as fuzes, decoys, and ejection seat units.
4. Dual-Voltage / Multi-Output Batteries
Designed to supply multiple power lines or voltages simultaneously from a single stack—ideal for advanced guidance or dual-mode fuzing applications.
5. Extended-Life Thermal Batteries
Engineered with optimized materials and insulation for prolonged high-temperature performance, especially in multi-phase operations or long-duration missile flight.
Activation Mechanisms (Independent of Battery Type):
1. Electrical Activation
Triggered by an electrical current delivered to an internal squib or resistor, initiating a pyrotechnic reaction.
Applications: Guided bombs, cruise missiles, UAV payloads.
2. Mechanical Activation
Initiated by a spring-loaded striker or percussion mechanism upon impact or acceleration.
Applications: Smart bom kits, submunitions, anti-tank mines.
3. Inertial Activation
Triggered by sudden G-forces or deceleration events during launch. These systems are sealed and fire automatically upon dynamic force.
Applications: Tactical rockets, spin-stabilized projectiles.
At PILTEK, the development of thermal batteries follows a multidisciplinary engineering approach that combines electrochemistry, thermodynamics, mechanical design, and system integration. Each solution is customized to meet platform-specific requirements and environmental constraints.
Our design process begins with advanced simulation tools to model:
Heat propagation across cell stacks during activation
Material behavior under thermal shock and rapid phase change
Current flow and power output in real-time conditions
These simulations ensure optimal cell architecture, separator materials, and heat source parameters for each application.
We tailor each battery to the physical and electrical needs of its platform:
Custom housings and form factors for integration into constrained spaces (e.g., conformal designs)
Connector and terminal configuration per customer specifications
Shock and vibration resilience for missile and artillery-grade requirements
Based on system demands, we develop the appropriate activation method:
Electrical igniters for programmable, precise actuation
Mechanical strikers for passive, rugged systems
Inertial triggers for high-G projectile applications
Custom hybrid solutions for dual-phase mission profiles
Prototypes are rapidly fabricated in-house for:
Thermal cycling tests
Output verification under simulated conditions
Inertial triggers for high-G projectile applications
Form-fit-function evaluations
This early validation shortens development time and ensures mission reliability.
From concept to deployment, our engineers work closely with system integrators to align the battery with mission parameters such as:
Voltage and current profiles
Activation delay time
Required operating temperature and pressure range
Maximum allowed weight and volume
Environmental and safety requirements (MIL-STD-810H)
By blending simulation-driven design, hands-on prototyping, and system-level engineering, PILTEK delivers thermal battery solutions that are optimized, robust, and battlefield-proven. Our ITAR-free development platform ensures secure and scalable supply chains for domestic and allied partners.
PILTEK's manufacturing infrastructure is purpose-built to deliver high-performance thermal batteries that meet the demanding needs of defense and aerospace applications. From raw material preparation to final qualification testing, every stage is managed with precision, traceability, and compliance to military standards.
We begin with in-house processing of critical electrochemical materials to ensure consistent quality:
Powder Preparation – Milling (ball mill, jaw crusher) and classification
Mixing & Homogenization– V-blender, 3D mixer systems for uniform composition
Anode and Cathode Material Formulation – Proprietary recipes for optimized performance
Our controlled processes ensure repeatable and high-density cell stack construction:
Cold Pressing – Uniaxial and hydrostatic pressing for electrode pellets
Dry Room Assembly – ISO-class humidity-controlled environment to prevent degradation
Automated Sub-Assembly – PLC-controlled systems and robotic arms for precision alignment
Header and Case Manufacturing – Precision-machined housings and terminals
Glass-to-Metal Feedthrough Integration – For hermetic sealing and electrical connectivity
Explosive Igniter and Pyrotechnic Capsule Production for high-G projectile applications
We utilize advanced joining methods for mechanical integrity:
TIG / MIG Welding
Laser Spot Welding (optional)
Hermetic Sealing Validation
All batteries undergo rigorous inspection at multiple stages:
Leak Testing – Helium leak detection, pressure decay methods
Electrical Testing – Continuity, insulation resistance, terminal verification
Functional Testing – Custom test rigs simulating real mission conditions
Environmental Qualification – According to MIL-STD-810H for temperature, humidity, vibration, and shock resistance
Compliant with Dangerous Goods Regulations (DGR)
Shock-absorbent and sealed packaging for storage and transport
Serialized tracking and documentation for defense traceability
Facility Highlights
Capable of producing > 10,000 units/year
1300 m² production area
90 m² dry room (ISO Class, Cleanliness Protocols)
Explosive Capsule Production
By combining advanced material handling, automated assembly, and mission-grade testing, PILTEK ensures thermal batteries that are robust, consistent, and field-ready. Our vertically integrated process minimizes supply risk and maximizes responsiveness to evolving defense needs.