STIHL battery production
How is a professional STIHL battery created? Read our article to find out more about battery production at the STIHL headquarters in Waiblingen in Germany. Take a look at our video to hear more about the process.
21.07.2026
Overview: Battery production
- We have been producing cordless products at STIHL since 2009
- We produce batteries in-house in Waiblingen, Germany, including the professional backpack batteries AR 2000 L and AR 3000 L from the AP System
- Production has many steps, from cell holder preparation to end-of-line test
- Maximum precision and various quality assurance measures are required to produce premium batteries
Battery expertise at STIHL
STIHL already has many years of battery expertise, as we have been manufacturing cordless products since 2009.
In 2016, the STIHL competence centre for battery and electric technology was established to combine the development of powerful battery and electric technology and to meet STIHL’s demand for performance and durability in modern cordless power tools.
Since 2018, STIHL has also been operating its own battery production facility in the same location as our development and competence centres.
How are STIHL batteries made?
What production steps are necessary and how does STIHL ensure that all of our batteries meet the high quality requirements during production? Take a look at our guide to battery production below.
In the first step, the cell holder, into which the battery cells are later inserted, is automatically fitted with special deflector plates. These contacts between the cells are laser welded to ensure they withstand high loads and give them a long service life.
STIHL uses Poka Yoke, a simple fault prevention technique, in this production step. The deflector plates can only be installed in the correct position. The cell holder is then transported to the next production line.
Once there, the prepared cell holder is equipped with battery cells by a pick-and-place robot. Two placement wheels present the battery cells in the correct orientation, which the robot extracts according to the respective placement pattern. In this battery production step, 60 battery cells are used for a STIHL AR 2000 L and a total of 90 battery cells for a STIHL AR 3000 L.
STIHL plastic production: STIHL’s own plastic production facility manufactures numerous plastic parts for the batteries, such as the holder for individual battery cells and the battery cover.
After the bottom cell holder has been equipped with battery cells, the top cell holder, which is also fitted with cell connector plates, is placed in the joining station and the battery cells are joined together. During this production step, the joining station automatically measures the force and distance to only send optimally joined battery packs for further production.
In the next step of battery production, the main electronics and sensors are inserted. First, the deflector plates are welded with high precision to the crimps of the electronic power line cables in a fully automated process. Then, among other things, temperature sensors are installed. These regulate the heat in the battery in order to prevent damage from overheating during use. After that, the medium-voltage taps are mounted using a patented design and also welded fully automatically.
Now the battery pack is fitted with a control unit. This is plugged in and wired first before the pretest is performed. This test verifies the proper functioning of the electronics with a beep.
This ensures that each manufactured battery pack functions correctly. This procedure reduces waste and contributes to sustainable production, as the controls can be replaced before casting and the battery pack can continue to be used if the pretest does not confirm proper functioning.
The battery pack and control electronics serial numbers are then married together. In this way, it is possible to see which specimens are installed in the finished professional battery. After passing the pretest, each specimen is prepared for casting.
The polyurethane encapsulation insulates the electronic components and protects them from moisture and mechanical influences. In the casting machine, the compound is applied under the PCB first to remove air. The polyurethane then rises until all components are covered. After the casting compound has hardened, the battery is ready for final assembly.
The first part of the final assembly is visually inspecting the casting and validating it with a white pen. The ergonomically shaped back plate is then mounted and equipped with fasteners and the handle. The operating unit is then plugged in and the front hood is attached. Before it is fed into the screwing station, the contacts are oiled as a preventive measure to ensure that they remain easy to connect for a long time.
The end-of-line test checks the functionality of the entire battery. For this purpose, the display LED is checked, the latest software is flashed, and all technical functions are tested to ensure safety during use in the field. After the inspection, all component labels are scanned and thus uniquely assigned to the specimen. The battery is only released for use once it has passed the test and the components have been assigned.
Finally, the professional battery is packed along with the accompanying documentation.
Important considerations in battery manufacturing
Electrostatic discharges pose a significant risk throughout battery production. Employees therefore wear special dissipative work clothing to effectively protect the still unprotected electronic components during production.
From cell assembly to end-of-line testing, STIHL has installed various quality assurance processes to provide the best quality for charging and use.
The sensitive components do not allow any error tolerances in the production processes. That is why every step of battery production requires maximum precision so that the finished battery meets the high quality standards we and our customers expect.
Next Level Power. All day long.
The ALLPRO Battery System has been developed to meet the needs of professional users, who demand outstanding performance, maximum efficiency, and a longer lifespan for their batteries.
With up to 60% higher peak performance1, the system delivers the capacity required for the most demanding tasks. At the same time, the quick-charging function minimises interruptions thanks to a charging time of just 9 minutes2. Your batteries also remain fully operational even in wet and rainy conditions3 and the ALLPRO batteries have a lifespan of over 3,000 charging cycles4. This guarantees reliable performance without any loss of efficiency over the years, reducing your operating costs overall.
1 Comparison with AP 300.0 P(C) and AP 300 S.
2 Time taken to reach 80% charge at ambient/battery temperatures of 25–40 °C when used with the AL 1802 MO. Applies to ALLPRO batteries AP 100.0 P, AP 200.0 P and AP 300.0 P(C).
3 IPX5 protection applies only to ALLPRO batteries AP 100.0 P, AP 200.0 P and AP 300.0 P(C). The ALLPRO batteries AP 20.1 and AP 30.1 are IPX4-certified.
4 Up to 3,000 cycles without noticeable loss of performance; can still be used thereafter. Applies only to ALLPRO batteries AP 100.0 P, AP 200.0 P and AP 300.0 P(C).
