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How do I get MAL power systems in my region?

With new government regulation and the the weaknesses of fossil-fuel based solutions, large automotive manufacturers are carefully planning their roll-outs for new high-tech vehicle designs, and their CO2-free power systems must be ready by as soon as 2024.

Our intention is to ensure that manufactured power packs are made available as soon as possible for car manufacturers to install in new and converted vehicles. And agents working with MAL recognise the opportunity of collaborating with multiple partners to ensure that all of the correct suppliers are in-place locally to achieve the desired cost-per-kilometre for the driver.

To support this process, this page will help both potential clients and agents understand the steps that would need to take place within a region to ensure that power packs are installed safely, economically and within a network that is truly CO2-free.

Stage 1: What business describes you best?

Before exploring the steps for making our technology available within your region, this step involves establishing the form of business that describes you best. This will provide an understanding of how you will first interact with us as an agent or client, and the other suppliers that we will need to collaborate with.

Stage 2: Establish the category of the final intended client

This first step involves establishing the category of final intended client (see example categories 1 and 2 in stage 3) of the power pack system. This could be an organisation related to garages and service stations that intends to offer car conversion services to its existing user base. Or this could be a car manufacturer that intends to integrate our power systems into vehicles still in production. 

This will be the organisation that sells vehicle conversion services or already-converted vehicles to the end user, and all the remaining steps are to ensure that the correct local suppliers are in-place to manufacture and transport the power packs required to this final client; and to ensure that this supply chain is efficient enough for this final client to offer refuelling services at a competitive cost-per-kilometre.

To understand these two forms of final intended client, use the buttons below:

Stage 3: Establishing existing capabilities of the final intended client

The final intended client could be a vehicle manufacturer, a taxi company or a station network. Whatever role our MAL power systems play in their business model for the end user, the final intended client may have capabilities that -  if taken over from MAL - could reduce the quotation for installation kits (the power pack and tools needed to convert a car for the first time); and a reduced quotation for refuelling kits (the set of modules, cells and/or materials needed to refuel an installed power pack design). 

To understand the different licence functions behind the manufacturing process, take a look at the interactive diagram below:

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Category 1: For example, a next-generation car manufacturing startup seeking to install our power packs into their vehicles during the production process will likely also have capabilities such as case manufacturing capability, and an existing network of service stations. This form of an organisation would be able to pay for a combined manufacturing licence to leverage these in-house capabilities, secure exclusivity of manufacture within a defined region, and benefit from a reduced quotation for the power packs when ordered. During the first term of this combined manufacturing licence period (1-2 years), an optimised power pack design will be prepared and the following missing licensees within the local area will be brought onboard:

  • Metal processing supplier

  • One of the component manufacturing licences (i.e., either cell manufacturing or case manufacturing)

  • Transport and storage supplier

Category 2: Conversely, an organisation focused on servicing existing cars with conversion and refuelling services will likely have capabilities such as a network of service stations; transport and storage; but not manufacturing capability. This form of an organisation would also be able to pay for a combination of licences to leverage these in-house capabilities, benefit from some exclusivity within their local region, and similarly benefit from a reduced quotation for the power packs when ordered. During the first term of this combined manufacturing licence period (1-2 years), an optimised power pack design will also be prepared; the organisation will be able to sell pre-order tokens for conversion services to their existing clients; and the missing licensees below within the local area will be brought onboard:

  • Metal processing supplier

  • A cell manufacturing manufacturing licensee 

  • A case manufacturing manufacturing licensee

Stage 4: Generating the non-optimised quotations for the final intended client

Once you have identified the closest category of the final intended client (Category 1 or 2) and the function licences they can add based on their existing capabilities, this stage involves generating the price quotations for their final power pack design based on specifications desired by the client and commercial factors.

First, locate the calculator Power Pack Performance Calculator using the button below and enter the dimensions of the planned power pack design provided by the client. This will generate the estimated performance metrics for Power (W), Energy (Wh), Mass (kg) and Range (km). This will generate an estimate of what the 'non-optimised cost' would be for the installation kit (£) and the refuelling kit (£) models at the end of the first phase of the manufacturing licence period. In addition, the bottom of the calculator will generate the target cost per installation kit and refuelling kit for optimum cost of £0.08 per kilometre for the final driver to be achieved.


In the next stage, these non-optimised cost values will be optimised based on the licensable capabilities identified in the previous stage and options related to metal processing.

Stage 5: Generating the optimised quotations for the final intended client

Once you have generated the estimated non-optimised costs for the installation kit and the refuelling kit, you will then need to copy and paste these values into the calculator Power Pack Costs & Profit Calculator. After you have entered these values, you will need answer the other questions based on the client's preferences and alternative power system under consideration.


This will create the estimated cost that would need to be paid (by the final intended client) for installation power packs and power packs for refuelling. This will also show the effective cost-per-kilometre for the driver and how this changes as each optimisation is applied. And this will also be able to be contrasted to the estimated final driver cost-per-kilometre for the original power system (i.e. Petrol) that was considered.


This will also create the optimised cost per installation licence, cost per refuelling kit and final driver cost-per-kilometre using the alternative of an MAL aluminium air power system with the same preferences. These quoted costs will at first not be too different from the non-optimised quotations from the other calculator, but you will then have the ability to reduce these quoted costs by selecting the licensed functions that the client can take onboard based on their capability. This will produce reduced quotations, and will already be very competitive for a range extender system where the cost-per-kilometre is less significant.

However, after reducing the quotations based on this licensing capability of the client, you will next need to enter the total number of kilograms able to processed per day by the local metal processor supplier. As you drag this slider, you will be able to see the optimum volume (kg) that is required to achieve the desired final driver cost-per-kilometre. 

Stage 6: Establishing a local metals processing supplier and profit share

Now that the quotations for the installation kit and refuelling kit models are optimised based on the capabilities of the client, this stage involves securing the required metal processing volume with the local metals processing licensee. This ensures that the waste aluminium from used power packs and other scrap materials can be recycled into High-Purity-Alumina (HPA): this is then sold to manufacturers developing applications such as touchscreen technology, power-efficient LEDs and other uses that reduce CO2 emissions in the global supply chain.

For each bulk sale of HPA, 65% of the total purchase price is retained by MAL and re-invested into facilities for manufacture and operations needed for the competitive cost-per-kilometre. However, the remaining 35% is not required by MAL and can be shared between the metals processor and other licensees on-top of their standard supplier payments. This stage involves establishing how this percentage will be shared between the metal processor, the other licensees, the region agent and other potential partners such as local government. This will also be similar to forming a JV partnership, ensuring that each party gains significant benefit from setting up a fully CO2-free ecosystem within a region. However, this will also prepare the guarantees needed for the final intended client that the desired final cost-per-kilometre for the driver can be achieved; and that the region agent can begin to make commissions on each bulk power pack order.

This stage is can also be completed during the first phase of the final intended client's combined manufacturing licence. This will ensure that the network of local suppliers is optimised in tandem with the optimisation of the power pack design during this 1-2 year period, maximising the client's options for deployment in addition to any agreed form of exclusivity. However, during early discussions with the potential client, either your agent organisation or the client pay for a Level A Conditional Network Licence (see details below) to secure temporary rights for regional exclusivity (contingent on further stages) as the configuration of the upcoming network is discussed. This will be agreed to in an MOU format and is the precursor to the larger project.

To gauge how much each licensee within the local network would be paid for standard supplier activities in addition to their HPA profit share, use our button below to access our Exclusive Manufacturing Calculator, and take note of the tool Power Pack Costs and Profit Calculator above to confirm the monthly volume (£) required in metals processing.

Stage 7: The final intended client begins a combined manufacturing licence with R&D

After securing their conditional network licence during stage 5 above, the client begins the first phase of their combined manufacturing licence. This period is expected to last between 1-2 years (though this can be discussed), and involves:

  • Regional or format exclusivity for the client to deter competing organisations from replicating the same supply chain within this region. This may also involve rights to a specific 'user application format' such as ground support equipment or 'taxi support' within a specified region.

  • Ensuring that the installation kit and refuelling kit models are optimised for the differences in the region and unique capabilities of the client.

  • Preparing new training packages and manufacturing processes that will be deployed to each licensee prior to manufacturing the first batch near the end of this period.

  • Weekly technical calls between the engineers of both teams to explore how the unique advantages refuelling kit model (i.e. in volume) may benefit from recent developments from the separate MAL project in cathode research and development. During these calls, recommendations may also be made as the client's engineers prepare proprietary connectors and devices that will be involved in the integration of each power pack within the vehicle design.

  • Towards the end of this first period of the manufacturing licence, arrangements will be made to demonstrate the final optimised power pack in the target vehicle. This can also be used by the client for PR purposes to promote the new capabilities (such as long range) of the soon-to-be-released vehicle.

To understand the structure of our Level B service that is delivered within this first phase of the client's manufacturing licence, take a look at the buttons below.

Stage 8: Local manufacture is ready and installation kits are deployed

Now that the local supply chain is ready, and the modified power system is tested for all required standards, and the minimum order quantity is confirmed; the client can now move from a Level B manufacturing licence to a Level C power system licence. This power system licence will be charged to the client in the form of quarterly payments based on:

  • The required number of new installation kits required per month x the agreed cost per installation kit licence

  • The number of new refuelling kits required per month x the agreed cost per refuelling kit licence

This power system licence will also continue all of the same rights to exclusivity agreed under the manufacturing licence. During this period, the client will have access to an app interface if options have been agreed to monitor active licensed vehicles; to monitor the battery percentage for active users; or to provide a custom app for drivers for added refuelling functionality.

For further information on our Level C power system licence, take a look at the resources below:

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