Development and testing of STIHL ALLPRO batteries
What makes a powerful battery system for professional use? The STIHL ALLPRO battery system is a result of sophisticated developments, the toughest tests and precise production. A look behind the scenes shows why pros trust ALLPRO.
04.09.2026
Overview: ALLPRO batteries - development and quality
Development and real-life testing: STIHL ALLPRO batteries are developed in Waiblingen and specifically designed to meet the requirements of professional users.
Temperature tests: To ensure reliable performance, the batteries are tested under extreme heat and cold conditions - from plus 50°C to minus 20°C.
Environmental and safety tests: Testing with rain, splash and jet water ensures safe use for demanding tasks in extreme weather conditions.
Mechanical load tests: Mechanical tests, such as the drum test and drop test, simulate the severe vibrations and impacts encountered during daily professional use.
Long-term tests in real-life use: In addition to bench testing, the batteries must prove themselves in field trials before they go into series production.
DEVELOPMENT in Waiblingen: design and real-life requirements
The STIHL ALLPRO system batteries are developed in southern Germany - at the Waiblingen site. This is where decades of experience from product development flow together with a deep understanding of the requirements of professional users.
“We know very well how our products are used and what our customers need.”
Jürgen Häberlein, Head of STIHL Development
To meet these requirements, STIHL developed its own battery system - tailored to its own power tools, operating conditions and the highest quality standards.
Development and testing in detail
Temperature tests: Reliable performance in heat and cold
rofessional users work in a wide range of climatic conditions. That’s why the STIHL ALLPRO battery system is designed for operating temperatures of up to plus 50 °C.
Thermal simulations are used early in development. They help to realistically assess heat developments at more than 50°C.
The cold test is carried out in a cold chamber. Thanks to an integrated cold-start function, the batteries remain reliably ready for use even at temperatures down to minus 20°C.
Environment and weather tests: protection against moisture in everyday professional use
In professional use, batteries are regularly exposed to rain, splashing water or moisture. To ensure safe operation, ALLPRO batteries are tested intensively under environmental influences.
These include tests with splashing, spraying and rainwater, which realistically recreate typical working situations. The aim is to ensure the functionality and safety of the battery in the long term, even under adverse conditions.
Charge cycle tests: designed for long service life
For pros, service life is crucial. That’s why STIHL tests ALLPRO batteries in a charge cycle test.
The evaluation of the charge cycles confirms a long service life of around 3,000 cycles without noticeable loss of power.
This means that the ALLPRO battery system exceeds the industry standard.
Real-life tests with pros: reliability under real conditions
In addition to all laboratory and bench tests, the batteries must prove themselves in real professional use. In collaboration with professional users, they are tested in real working conditions.
This also shows the interplay with the intelligent STIHL charging structure, which enables fast and battery-saving charging. Only when the battery has proven itself in development, on the test bench, and in real-life use is it ready for series production.
Manufacturing and quality control
Each individual cell is measured with high precision in production, particularly with regard to its voltage position. After integration and careful soldering of electronics and safety features, compatibility with STIHL power tools is guaranteed. Inspections during installation ensure that the highest safety standards are adhered to.
After final assembly, each battery undergoes a comprehensive quality check before leaving the factory.
Next Level Power. Noticeably stronger. All day long.
The ALLPRO battery system has been specially developed for the requirements of professional users who rely on outstanding performance, maximum efficiency and long-term use of their batteries in their daily work.
With up to 60 percent more peak power1, the system delivers the necessary power for the most demanding tasks. The high-speed charging function with a charge time of only 9 minutes2 reduces interruptions to a minimum at the same time. Your batteries remain fully operational even in rain and wet conditions3. The ALLPRO batteries have a service life of over 3,000 charge cycles4. This guarantees reliable use without loss of efficiency for years to come, reducing your operating costs.
1 Comparison with AP 300.0 P(C) and AP 300 S.
2 Time to reach 80% charge at ambient/battery temperatures of 25-40°C in combination with AL 1802 MO. Valid for ALLPRO batteries AP 100.0 P, AP 200.0 P and AP 300.0 P(C).
3 IPX5 protection only applies to ALLPRO batteries AP 100.0 P, AP 200.0 P and AP 300.0 P(C). The ALLPRO AP 20.1 and AP 30.1 batteries are IPX4 certified.
4 Up to 3,000 cycles without noticeable loss of performance; can still be used afterwards. Only valid for ALLPRO batteries AP 100.0 P, AP 200.0 P and AP 300.0 P(C).
Questions and Answers
STIHL tests its batteries well beyond what is customary in the industry. This includes environmental, temperature, mechanical and long-term tests that represent typical and extreme conditions from everyday professional life. In addition, the batteries are tested in real-life use with professional users. This combination of development, testing and real-life is crucial for ensuring that STIHL batteries function reliably in daily use.
Laboratory and bench tests are a central component of development at STIHL, as they enable reproducible and controlled stress scenarios. At the same time, that alone is not enough. That’s why STIHL batteries are also tested for professional use. Only the interplay between technical testing and real-life use ensures that the batteries meet STIHL’s high quality standards.
The battery, power tool and charging system are designed to work optimally together. This affects performance, safety, service life and charging behaviour. One example of this is special STIHL battery technologies such as tabless technology, which is designed for high performance and efficiency. Such technological decisions can only be implemented meaningfully if all system components are considered together.
The service life of STIHL batteries depends on several factors: the cell technology used and intelligent charging and discharging management. Extensive charge cycle tests and precise quality control in production ensure that the batteries can be reliably used in professional applications for many years to come. Integrated safety functions also ensure compatibility with older STIHL power tools.
