More Range, More Payload: Ukraine’s Race to Build Better Drone Batteries

The next breakthrough in Ukraine’s drone war may not be a new aircraft or weapon, but the battery powering it. Ukrainian battery maker PAWELL is betting on solid-state technology to make drones lighter, longer-range and capable of carrying heavier payloads, while seeking to scale production to as many as 10,000 battery units a day and reduce Ukraine’s reliance on foreign components.JOIN US ON TELEGRAMFollow our coverage of the war on the @Kyivpost_official. Pavlo Yesyp, PAWELL’s co-founder, told Kyiv Post that the company is developing new battery technologies for unmanned aerial vehicles (UAVs), electronic warfare systems and unmanned ground vehicles as Ukraine races to maintain its technological edge. Yesyp spoke to Kyiv Post after PAWELL took part in the world’s largest drone exhibition, where he said the scale of China’s technological development stood out most. “What impressed me most was the level of technological advancement China has achieved,” he said. He described seeing drone applications ranging from firefighting to systems designed to wash windows on high-rise buildings, saying there was “a distinct feeling that we were getting a glimpse into the future.” He added Ukraine remains highly competitive in military drone technology but said that Ukrainian companies did not have public exhibition booths, which he described as a security-driven decision given the presence of representatives from Russian military technology companies. Other Topics of Interest Russian Attack Cuts Kyiv Internet, Delays Trains Two internet providers reported outages after data centers were damaged, while Russian strikes caused major rail delays across Ukraine. For PAWELL, he said, the exhibition reinforced the need to develop domestic capabilities. “To maintain and expand our advantage, we must localize the production of all components in Ukraine as quickly as possible,” Yesyp said. “Our goal is to achieve maximum technological independence.” Moving beyond conventional drone batteries According to Yesyp, one of the company’s main areas of development is solid-state battery technology. He said most Ukrainian manufacturers and drone operators currently rely heavily on cylindrical battery packs using the 21700 format. PAWELL is instead developing solid-state systems, which replace the liquid or gel electrolyte used in conventional batteries with a solid material. PAWELL currently advertises solid-state battery packs for large unmanned aerial vehicles (UAVs). PAWELL’s product catalog lists solid-state battery packs ranging from 30,000 to 118,000 mAh, including a 118,000 mAh model designed for large UAVs. The company says its solid-state products can reduce battery weight by 30% compared with conventional lithium-ion alternatives of similar capacity. Yesyp said the weight reduction is particularly important for unmanned platforms because every kilogram saved can be allocated to additional equipment. “For UAVs, this is a critical advantage: the lower weight and stable operating temperature allow the drone to fly 30-50% farther while carrying a significantly heavier payload.” Batteries for drones made by PAWELL. (Photo courtesy of PAWELL) He said PAWELL is also working on sodium-ion battery packs, which he described as a lower-cost option for unmanned ground vehicles (UGV). Unlike lithium-based batteries, sodium-ion technology does not rely on scarce lithium resources, although Yesyp acknowledged that such batteries can be heavier. Scaling production during wartime PAWELL is targeting production capacity of up to 10,000 battery units per day, according to Yesyp, who said the goal is achievable despite the challenges created by Russia’s war against Ukraine. Security is the biggest obstacle, he said, making decentralization central to the company’s expansion strategy. Rather than relying on a single large facility, PAWELL plans to develop a network of smaller production sites and protected locations. The company says its batteries are manufactured in Ukraine, with its own production and research-and-development capabilities. Yesyp said the company is also applying LEAN management principles to standardize production, reduce waste and make facilities operate as a coordinated network. The broader objective, he said, is to build as much of the battery supply chain in Ukraine as possible. “Our strategic goal is to achieve 100% localization of production within Ukraine itself,” Yesyp said. He acknowledged that imported components remain part of the equation, particularly as Ukraine works with European partners and draws on technologies developed in Asia. But he argued that greater domestic production would reduce strategic dependence on foreign suppliers. Bigger drones could transform battlefield logistics Yesyp said drones capable of carrying payloads of up to 200 kilograms (440 pounds) over distances exceeding 250 kilometers (155 miles) could fundamentally change battlefield operations, moving beyond precision strikes toward what he called “scalable robotic warfare.” An engineer at Ukrainian battery maker PAWELL at work. (Photo courtesy of PAWELL) He said such systems could target ammunition depots, command posts and fuel storage facilities deep behind the front line, while also delivering heavy cargo and evacuating wounded troops. He linked these capabilities to the “Air-Land Economy” strategy championed by former Defense Minister Mykhailo Fedorov, which envisions unmanned and robotic systems taking on dangerous tasks on the ground and in the air, reducing the need to expose human personnel to risk. But Yesyp said such capabilities depend heavily on battery technology. “Lifting 200 kilograms and flying 250 kilometers requires energy of a completely different density,” he said, arguing that conventional batteries are too heavy for such applications. PAWELL’s solid-state technology, he added, is designed to provide the energy density needed for longer-range, heavier-payload drones. “Our innovative solid-state solutions provide the technological ‘foundation’ that delivers the necessary energy density, enabling the Air-Land Economy concept to function not just on paper, but in actual combat,” he said. Keeping production running under attack Maintaining manufacturing capacity while Russian strikes continue against Ukrainian infrastructure presents another challenge. Yesyp said PAWELL’s approach rests on three principles: decentralization, limiting sensitive information about production, and state support. “We cannot afford to operate by the old rules,” he said, arguing that a distributed production network allows other facilities to continue operating if one location is affected. He also stressed the importance of information security, saying companies must avoid publicly revealing details that could expose production facilities to attack. “That is precisely why, as I mentioned earlier, we did not set up public Ukrainian stands at the international exhibition,” Yesyp said. “The enemy constantly monitors the information space, looking for targets.” The next battery breakthrough Looking ahead, Yesyp predicted rapid development in battery technology over the next two to three years. He said PAWELL expects advances in power systems to significantly increase the endurance of different UAV platforms, while new battery chemistries could eventually provide alternatives to lithium-based technologies. “The lifecycle of any invention at the front is only three to six months – exactly the time the enemy needs to devise a countermeasure,” Yesyp said. “Consequently, we must win every subsequent cycle of innovation.” Yesyp said improvements in power systems are essential for increasing a drone’s range and payload capacity. “A drone’s ability to fly further and carry a heavier payload is made possible solely by improvements in power systems,” he said, adding that new battery chemistries are likely to emerge as lithium becomes increasingly scarce. Scientists worldwide are already working to develop alternatives and maximize the amount of energy that can be stored in increasingly compact battery systems, Yesyp added.