https://www.danielconsultinggroup.com/meettheteam daily 0.75 2025-07-07 https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1602874700114-3TG81RB81U4QZ2H1HB4U/reece-daniel-headshot.jpg Meet the Team https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/4aa507b4-9202-42dd-bac4-8fdabe05f445/BenHowell_04032025.jpg Meet the Team - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/c056bfc1-0004-4b68-9e01-02146a7d0d83/JohnLoftus_09112024.png Meet the Team - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/db3c72c3-eb6f-4118-a4c3-ea171ea003e7/IMG_1879.jpeg Meet the Team - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/87606ce7-e3cb-4dd2-9e4c-865d1aa5e555/GregRobben-bio.JPG Meet the Team https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/2130e97b-4e25-49ba-9a02-880bae55abd0/Noelia_Cura_05252024.jpg Meet the Team https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/4684c2ac-180a-42e5-ba74-db1f1aee4ebb/NEGHeadshot_07082025.jpeg Meet the Team https://images.squarespace-cdn.com/content/v1/5ce435d6bea1ed00016ba287/1558964652247-5MWXNMFZVOPGE4TY6U2Q/MHeiderich_ReflexionenZwei-05-copy.jpg Meet the Team https://www.danielconsultinggroup.com/general-4 daily 1.0 2025-09-03 https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603219399353-T2GXJ5UFU74XE3Y9A4IH/beta.png Home https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603816573826-CRWY9CB0YFB93SYLWGAD/AmbriLogo_10272020.jpg Home https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603679664790-I6CHM4UCUA1WGGTRILXU/Embr+logo.PNG Home https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603816235461-CWEAKDHSIZHBEQSCLC1Q/Energy_Assurance_Logo.jpg Home https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603219444674-1V75M5KBF6PRXTT2BKZ6/asumag_8781_mit_logo.png Home https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603816766363-4BZLIEUZQU7C6J8Q7CR1/TitanLogo_10272020.jpg Home https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603817047810-906VAAJTVRNXFHU4MXLR/FormLogo_10272020.jpg Home https://www.danielconsultinggroup.com/contact daily 0.75 2020-11-13 https://images.squarespace-cdn.com/content/v1/5ce435d6bea1ed00016ba287/1558964652247-5MWXNMFZVOPGE4TY6U2Q/MHeiderich_ReflexionenZwei-05-copy.jpg Contact https://www.danielconsultinggroup.com/our-services daily 0.75 2025-09-03 https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/7887f3c4-58bd-4bdc-b0f0-cd86f37ce73d/DCG+calibration+proof%282%29.png Our Services - Make it stand out Whatever it is, the way you tell your story online can make all the difference. https://www.danielconsultinggroup.com/new-page daily 0.75 2025-09-03 https://www.danielconsultinggroup.com/testimonials daily 0.75 2021-02-05 https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1612557000037-G62AS94T1J07UB8XIFZY/TitanLogoII_02052021.jpg Testimonials https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1608568403163-AAVF3LT3SQO3RV2ECY1T/FormLogo2_12212020.jpg Testimonials https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1608078548065-YKX8PBGX4V0W1LWCQA5S/Ambri_logo_forDCGwebsite_12152020.jpg Testimonials https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1607790660374-KPNWK7QD5BJO20TZM98D/BETAlogo_12122020.jpg Testimonials https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1607899847101-80WG01WOUVI67WRZ04T3/EmbrLabsLogo_12132020.jpg Testimonials https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1604005621064-CN6BZKSXD33YQRJ5UH7J/Energy_Assurance_Logo.jpg Testimonials https://images.squarespace-cdn.com/content/v1/5ce435d6bea1ed00016ba287/1558964652247-5MWXNMFZVOPGE4TY6U2Q/MHeiderich_ReflexionenZwei-05-copy.jpg Testimonials https://www.danielconsultinggroup.com/gallery daily 0.75 2020-12-16 https://www.danielconsultinggroup.com/gallery/cell-thermal-characterization monthly 0.5 2020-10-29 https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1604001228906-9K0P22YCRYSKNSHQW8RA/Thermal1_10282020.jpg Gallery - Cell-level Thermal Characterization This is some Isothermal Battery Calorimetry (IBC) work I did for a client in conjunction with a local partner lab. The (2) cells in this study correspond to (2) different commercial cylindrical cell brands. In this case, the client wanted to know A) how do the (2) cells compare against one another and B) how does the thermal performance of both cells change with different charge rates. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1604001287556-CJFIJ1EOJMLLE0N1I143/Thermal2_10282020.jpg Gallery - Cell-level Thermal Characterization The next thing we wanted to know was how heat generation data from the IBC compared what we predicted for these two cells from the cycling data. https://www.danielconsultinggroup.com/gallery/high-voltage-pack monthly 0.5 2020-10-29 https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1604000824510-E8M7NVNS5HIGSOMY9L8N/Pack1_10282020.jpg Gallery - High-Voltage Battery Pack Design This is a high-voltage battery pack design that I did for a client. To maximize on energy density, this pack makes use of next generation layered pouch cells. The opposing current collector tabs lower the volumetric energy density a bit, but help with thermal management by effectively eliminating hot spots within the cell. https://www.danielconsultinggroup.com/gallery/r-d-cathode-casting-study monthly 0.5 2020-10-28 https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603922535731-M4Z5GO1ID8WZKJ1SZYL8/Cathode1_10282020.jpg Gallery - R&D Cathode Casting Uniformity Study For R&D cells, getting an accurate mass for your cathode active material is absolutely crucial. Unfortunately, weighing individual R&D cathodes can be expensive and time consuming. Therefore, this customer wanted to know if they could get away with using a nominal cathode weight instead. As a first step, we did a standard cathode casting, tracked all of the cathodes that came from it (left), and mapped out their masses (right). https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603923283573-ZL9VDNNXH4IKFPUMV62H/cathode2_10282020.jpg Gallery - R&D Cathode Casting Uniformity Study We repeated this process for (2) castings and looked at the data. The most striking observation was the fact that all of the cathodes with masses > 1 standard deviation below the average seemed to come from the same location on the casting. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603923755791-WEZJXS8EQ47IP4N0W5BZ/cathode3_10282020.jpg Gallery - R&D Cathode Casting Uniformity Study Here's how the mass distribution looks for both cathodes combined, with and without the troublesome section included. By simply discarding this section of the casting we were able to reduce the standard deviation but the yield dropped by 10%. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603924105271-JCW4Z5CIAGDHQTDY3P4X/cathode4_10282020.jpg Gallery - R&D Cathode Casting Uniformity Study In a slightly-related test, we then wanted to know how weighing cathodes inside the glovebox vs. outside in the lab affected the measured mass. Gloveboxes make everything harder, so if a delicate process like cathode weighing can be done in the lab instead, it could shave off some valuable R&D time. https://www.danielconsultinggroup.com/gallery/vacuum-suitcase monthly 0.5 2020-10-29 https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603920107680-FMHBXP1CN7DMJ8FVRO7C/Vac1_10282020.jpg Gallery - Vacuum Suitcase This is a custom piece of equipment that I designed and built called a Vacuum Suitcase. This particular unit was designed to transfer samples of cathode material from an inert glovebox atmosphere on the 4th floor to an X-ray Photoelectron Spectrometer (XPS) located in the basement, all without exposing the samples to air. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603921032788-US1FV1RCLX6Y2BGFPJBL/Vac3_10282020.jpg Gallery - Vacuum Suitcase Here's a close-up of the final product. Last I checked, this is still being used today! https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603920942390-9YSQKYCT9HVY1B6V90JI/Vac2_10282020.jpg Gallery - Vacuum Suitcase Lots of interesting challenges and design constraints to work through on this project. The sketch on the right is the final design we decided on, and the picture on the left is the actual product. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603921226614-NT1M82TYX6IPFIGNKFXD/Vac4_10282020.jpg Gallery - Vacuum Suitcase Here's another picture of the final product with all of the components labeled. https://www.danielconsultinggroup.com/gallery/pouch-cell monthly 0.5 2020-10-28 https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603837786851-2YOFA0S55A5FBAF4HC51/prism1_10272020.jpg Gallery - 500 mAh Pouch Cell As far as I am aware, this is the largest magnesium-metal cell ever made. The top row are the (3) double-sided cathode layers. The middle row are the same cathodes above after being sealed in their separator baggies. The bottom row are the (3) Mg metal anodes. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603838125164-T8VLTYO2JZO4JM7422Y5/prism2_10272020.jpg Gallery - 500 mAh Pouch Cell Here we can see all of the components of this first prototype stacked pouch cell. By the markings on the bag in the bottom left corner of the screen, I am reminded that this ended up being a 500.2 mAh cell, but close enough.... https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603838324452-22Y17HDLHOQ96HRAZGYI/prism3_10272020.jpg Gallery - 500 mAh Pouch Cell On the left you can see the complete cell stack just prior to being sealed in the polymer pouch. On the right are (4) nearly-finished stacked pouch cells. https://www.danielconsultinggroup.com/gallery/test-chamber monthly 0.5 2020-10-29 https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603829852776-XL4KCDWIQIPL4AXZHB53/IMG_9585.JPG Gallery - Controlled Temp Test Chamber 144-channel controlled temperature cell testing chamber. Chamber is made by Cincinnati Sub-Zero (CSZ) capable of humidity control and temp control from 2*C - 70*C. In practice, this setup was able to maintain all cells on test at the desired temperature within +/- 0.5*C. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603829896592-FSTNUIC38D7ZNSTD20VA/IMG_9583.JPG Gallery - Controlled Temp Test Chamber Each 5V6A test channel is fed into one of the (144) apartment-style mailboxes inside. The fit of these mailboxes was so tight that we had to temporarily remove some screws from inside the door frame in order to slide it in! https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603831076897-ZUMWNFSTPZUX7LEIGGZ1/IMG_0352.JPG Gallery - Controlled Temp Test Chamber This is a picture of one of the columns of mailboxes in the chamber. The mailboxes themselves are off-the-shelf units, with (2) 4 x 5 modules stacked on top of one another. The rack holding them together was custom made. This was a very tight fit and we ended up having to remove the very top row so that each column contained (72) boxes instead of (80). https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603829964155-WO10YTA2XMITKEEXARYY/IMG_9591.JPG Gallery - Controlled Temp Test Chamber We ended up setting up (3) of these chambers and regularly had all (432) test channels running 24/7. These chambers were also tied into a ducting system in the back that was triggered to open by a smoke detector located inside of each chamber in the event of a battery fire. This system has been responsible for detecting and safely containing over a dozen battery fires since its inception. You can see a very tiny piece of the duct work at the very top-center of the chamber on the far left. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603832204517-3MCL8RLLYISZ3U3PV8CD/CSZHolePatter_10272020.jpg Gallery - Controlled Temp Test Chamber This is the original hole-cutting guide I sent to CSZ when we ordered the chambers. The bottom (2) rows of holes are feeding in the cables from the battery testers. The top row of smaller holes is where the smoke-triggered exhaust system connected to the chamber. https://www.danielconsultinggroup.com/gallery/coins monthly 0.5 2020-10-27 https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603836245123-BCUFZEYT9QV9EXMLR07O/coins1_10272020.jpg Gallery - 3-Electrode Coin Cells This is from a 3-electrode coin cell program I set up a few years ago. 3E coins are great on paper, but very difficult to execute consistently in practice. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603836257128-R81OH0TU89SLHZBCZYWK/coins2_10272020.jpg Gallery - 3-Electrode Coin Cells On the left you can see an image of a completed 3E coin cell. The bullet points on the right list some of the strengths and weaknesses of using this configuration as a main test vehicle for your R&D program. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603836267082-1M8G4YZV61EGEYO6UIO4/coins3_10272020.jpg Gallery - 3-Electrode Coin Cells I put together this image to describe the most common failure mode I was seeing in this configuration: soft-shorting of the reference electrode to the working electrode above. https://www.danielconsultinggroup.com/gallery/drone-test-rack monthly 0.5 2020-10-27 https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603833475049-H8RU70SUT8CKQK3V0TSS/10BitChallenge_chargingrack_10272020.jpg Gallery - Drone Pack Testing Rack This rack was designed for testing drone packs. It consists of (2) rows of (5) modular lockers (12”W x 13.5”H x 15”D), back-to-back with a 3” gap in between. We used (2) commercial 36'' 420 CFM range hoods side-by-side for our ventilation. The side supports and the adjoining ducting were fabricated in-house. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603833769381-AW500W0OB7US5IWHH7PF/10BitChallenge_fluliners_10272020.jpg Gallery - Drone Pack Testing Rack Clay flue liners are fantastic. They are a cheap and robust way to isolate your test channels from one another to prevent propagation in the event of a battery fire. They also fit quite snugly inside of a standard 1' x 1' x 1' locker. These are the cut instructions I provided to our contractors for this project. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1604002644076-HOOZ5P3NTAQCSUUUO6FB/packrackB2_10292020.jpg Gallery - Drone Pack Testing Rack The customer was so happy with their first rack that they asked me to design a second one for them. This rack consists of another (20) test channels, arranged in (2) rows of ten and installed on a tabletop. Like the other rack, the back of all these lockers is open and enclosed by a sheet-metal box. Ventilation is achieved through ducting connected via the 6" diameter hole on top. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1604003016288-MBE98BLF2VXBEEMRXSI1/packrackB1_10292020.jpg Gallery - Drone Pack Testing Rack Here's the same rack but with the lockers removed on the (6) channels to the far right, exposing the inner structure of the test channels. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1604003246344-KZJZP21HYRHTTGOCQSWH/packrackB3_10292020.jpg Gallery - Drone Pack Testing Rack This is an exploded view of one of the lockers. Front-to-back you can see the actual locker itself in Blue, the clay flue-liner in Orange, the clay flue-shelf behind that, a Black micro-controller box that sits under the flue-shelf, and finally at the very end we have the ceramic insulation lining in Grey. All of this might seem like overkill, but when you're testing a novel high-energy battery chemistry, a set-up like this can mean the difference between burning your lab to the ground vs. cleaning up a small mess in the morning. https://www.danielconsultinggroup.com/gallery/rd-lab monthly 0.5 2020-10-27 https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603826844806-89YDZIMGCAHTQ97SDKN9/IMG_9563.JPG Gallery - R&D Cell Testing Lab Set-up Panoramic view of a R&D Cell testing area. All of these lockers are located under a 12' x 12' viking-style hood that provided constant airflow and ventilation for the ~500 cells under test. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603826953587-JH5ZHHSCIX03ZWBT15NJ/IMG_9573.JPG Gallery - R&D Cell Testing Lab Set-up R&D Cell Testing Lab Set-up. Note that the Neware Battery Testers have been broken up into columns of 2-3 modules and suspended overhead. This is a great way to maximize on floor space without sacrificing test channels. https://images.squarespace-cdn.com/content/v1/5f89da86a40073181a8791bb/1603828197618-RGXI1EAGN857K1QO0GLI/L4Layout_10272020.jpg Gallery - R&D Cell Testing Lab Set-up High-level schematics for planning out this R&D space. The blocks in Yellow and Green are cyclers - the yellow means it's suspended overhead, green is on the ground. The large Grey block in the middle represents the footprint of the 12'x 12' viking-style hood overhead. The small Beige and slightly larger Dark Grey blocks represent individual lockers for test channels. The Beige lockers can hold up to (12) test channels and the Dark Grey lockers can hold up to (18) test channels of a slightly larger form-factor cell.