Batteries & Energy Storage

Batteries are essential to nearly every aspect of modern life. From everyday consumer electronics like smartphones, tablets, and smartwatches to household products such as power tools, vacuums, and heaters, and even critical applications like medical devices, electric vehicles, and utility-scale battery energy storage systems (BESS), batteries power the technologies we rely on.

Whether it’s alkaline, lithium-ion, nickel-metal hydride, or lead-acid batteries, each chemistry comes with its own unique performance characteristics and use cases. At Secretariat, our engineering consultants provide expert support across the entire battery product lifecycle, from design and manufacturing to deployment, diagnostics, and end-of-life considerations.

With hands-on experience in both the production and real-world application of batteries, our team brings deep technical insight into battery performance, safety, failure analysis, and quality assurance.

Key Experts

Sam Madden

Director

Areas of Expertise

Battery & Pack Design and Validation

Designing and validating modern battery systems requires a careful balance of safety, performance, and manufacturability. From concept through DVP&R planning and execution, we draw on direct experience with new product introduction (NPI) cells, lab development, and OEM-level validation. Our guidance ensures your product stands up to real-world demands.

Materials for Energy Storage

Battery performance hinges on decisions made at the materials level. We provide insight into active materials, electrolytes, separators, and interfaces, helping clients solve degradation issues, compare chemistries, and scale R&D innovations. Our approach combines lab knowledge, electrochemistry fundamentals, and real-world application needs.

Facility & Technology Safety Assessments

Establishing or expanding battery operations involves critical safety and process considerations. We offer independent assessments of lab and facility design, abuse and thermal risk protocols, and process workflows. Whether you are building a test lab or auditing production readiness of a supplier, we help make sure safety and efficiency go hand-in-hand.

Technology Evaluation

With battery innovation moving fast, it is not always clear which technologies or claims will hold up under pressure. We can support investors, acquirers, and internal teams with technical due diligence, benchmarking, and roadmap reviews, helping you make informed decisions grounded in hands-on engineering experience.

Fractional Technical Leadership

For organizations in need of deep battery expertise without a full-time hire, we offer fractional leadership across validation, testing, and program execution. Whether bridging a capability gap or driving a new initiative, we integrate quickly, lead effectively, and bring structure and clarity to complex technical programs.

Battery Failure Analysis

When batteries underperform, swell, leak, or burn, the root cause can be complex and multifactorial. We conduct in-depth failure analyses on cells, modules, and packs to identify mechanical, electrical, chemical, and thermal failure modes. Drawing from real-world incident data and lab diagnostics, we help clients understand what went wrong—and how to prevent it in the future. Whether supporting safety investigations, product recalls, or quality improvements, our findings are grounded in rigorous engineering and materials science expertise.

Expert Witness Services

Whether it be battery failures, intellectual property disputes, or product claims in legal actions, we provide independent expert witness support grounded in deep industry experience. We work closely with the clients to deliver clear, defensible, independent technical analysis and testimony across a wide range of energy storage matters.

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