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.
31.07.2026
Overview: ALLPRO batteries - development and quality
Real-World Development and 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: Tested in rain, splash, and water-jet conditions, it's built to deliver reliable performance in demanding work environments and extreme weather.
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 Testing Under Real-World Working Conditions: In addition to bench testing, the batteries must prove themselves in field trials before they go into series production.
Developed in Waiblingen: Engineered to Meet the Demands of Everyday Work
Designed and developed in Waiblingen, Germany, STIHL ALLPRO batteries are built on decades of product development experience and a strong understanding of real-world professional demands.
“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.
Inside the Development and Testing Process
Temperature Testing: Reliable Performance in Hot and Cold Conditions
Professional users count on their equipment in all types of conditions. That's why the STIHL ALLPRO Battery System is designed to provide dependable performance in temperatures of up to 50 °C.
Thermal simulations are used early in the development process to evaluate battery performance under high-temperature conditions exceeding 50°C. Cold-weather testing is conducted in specialized climate chambers, and an integrated cold-start function helps ensure reliable operation in temperatures as low as -20°C.
Environment and Weather Testing: Designed for Professional Use in Challenging Weather Conditions
Professional users frequently work in rain, wet conditions, and other challenging environments. That's why ALLPRO batteries undergo rigorous testing for exposure to rain, splashing water, and moisture.
By replicating real-world job site conditions, these tests help verify long-term performance, reliability, and safety, ensuring ALLPRO batteries are ready for demanding work environments.
Charge Cycle Testing: Built for Long-Lasting Performance
For professionals, long battery life is critical. That's why STIHL rigorously tests ALLPRO batteries through thousands of charge cycles.
The results demonstrate up to 3,000 charge cycles with minimal loss of performance, helping the ALLPRO battery system exceed industry standards for durability and reliability.
Field-Tested by Professionals: For Proven Reliability and Performance in Real-World Conditions
Extensive lab and bench testing are just the beginning. ALLPRO batteries are also field-tested by professionals in real-world working conditions to validate their performance, durability, and reliability on the job.
These evaluations also confirm the effectiveness of STIHL's intelligent charging system, which delivers fast, efficient charging while helping extend battery life. Only after successfully meeting STIHL's standards in development, laboratory testing, and real-world field use do ALLPRO batteries move into production.
Manufacturing and quality control
Every battery cell is carefully measured and tested during production to ensure consistent performance, including precise voltage matching. After the electronics and safety systems are integrated, compatibility with STIHL power tools is verified. Multiple inspections throughout the assembly process help ensure the highest standards of quality and safety.
Before leaving the factory, every battery undergoes a comprehensive final inspection to confirm it meets STIHL's standards for performance, durability, and reliability.
Professional-Grade Power. All-Day Performance.
Designed for professional users, the ALLPRO battery system delivers the high performance, efficiency, and long-lasting reliability needed to power through demanding work every day.
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 10 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 P C and AP 300 S.
2 Time to reach 80% charge at ambient/battery temperatures of 25-40°C in combination with AL 1602 MO. Valid for ALLPRO batteries AP 200 P and AP 300 P C.
3 IPX5 protection only applies to ALLPRO batteries AP 200 P and AP 300 P C. The ALLPRO AP 20 and AP 30 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 200 P and AP 300 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.
