Dumarey Battery Energy Storage

Sheet metal enclosure for Dumarey’s battery energy storage product

Dumarey Green Power are a technology company focused on helping customers to save energy, reduce power supply requirements and minimise their CO2 footprint.

Their Revolution Battery addresses a niche in the market for a low-energy, high-power solution. Most battery energy storage systems (BESS) offer a steady power output over a prolonged period. Revolution Battery is designed for a high-power output over a shorter period – delivering 300kW of power from a compact, 28kWh battery pack. This makes it ideal for scenarios which have peak power output requirements – for example, the construction market.

The Revolution Battery is Dumarey Green Power’s first battery energy storage system. The design of the unit had to sit within the suite of their wider product range, whilst addressing the challenges of size, weight, assembly packaging, and structural strength.

As part of the Dumarey product development process, Finite Element Analysis (FEA) was utilised on the Revolution Battery assembly to predict real-world situations such ultimate load, vibration and shock.

Dumarey approached Universal Wolf with an initial product design, and we worked with them to develop it.

Working in partnership to meet tight deadlines

Universal Wolf was involved with the design development of the Revolution Battery from the start of the process.

We talked with the team at Dumarey to understand their desired output and advised how best to achieve this. We assessed their design and gave recommendations on the best ways to fabricate the metalwork for repeatable manufacture.

Among the key points to consider were the size of the sheet metal components and how best to fabricate them, materials selected to match the structural safety requirements, and maintaining clear communication between the project teams at Dumarey and Universal Wolf whilst working to tight timelines.

The FEA approval process highlighted some stress areas. We have a wealth of experience in addressing build challenges and adapting designs, and our team guided Dumarey on how to mitigate these. We helped with adjusting weld placement, suggesting higher-strength materials, and sourcing thicker off-the-shelf sections.

Once the team had an FEA-compliant design, we moved to pre-production of the sample units.

We used our Design for Manufacturing (DFM) expertise to guide the design reviews and sampling process. Our engineers partnered with the team at Dumarey, holding bi-weekly meetings and each travelling between sites to review and sign-off builds. We were transparent in showing Dumarey each step of the build and providing regular updates, which helped their team to mitigate potential issues.

The final sample was manufactured, signed-off and delivered in time to meet the customer’s deadline for a UK trade show.

A successful launch to the market

Our ability to adapt to and respond to customer requirements through the build process – be that tight timescales, changing product requirements, or sheet metal design iterations and updates – was crucial for the successful development of the Revolution Battery product. Our experience of revision control was also essential.

Richard Hill, Senior Project Engineer at Dumarey, said:

“Universal Wolf has helped us tremendously with the development of our Revolution battery product. The product was launched to the market in September 2024, and we wouldn’t have got this over the line without all of the support from Universal Wolf on fabrication and product design.

We look forward to working with the team in the coming years.”

“It is great working with the team at Universal Wolf. They are a key business partner for us and we are grateful for their continued support.”

Jon Drakeley, Operations Director, Dumarey

The first samples of the Revolution Battery are now in the marketplace with a strong customer reception. We look forward to supporting Dumarey with the continued refinement of the product.