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About Us

Since 1963, Lester Electrical has been designing and manufacturing industrial battery chargers and other electrical power conversion and storage products in Lincoln, Nebraska. Our first battery charger was produced for use with electric golf cars. Since that first product, we have released industrial and commercial battery chargers for most applications and markets, including golf, floor care, industrial/utility vehicles, electric vehicles, material handling, aerial work platforms, wheel chairs, and stationary/reserve.

Lester Electrical is the worldwide leader in industrial battery chargers. Our engineering/manufacturing expertise and flexibility have made us an OEM and ODM supplier to industry-leading companies in all major electric vehicle/machine markets. We are also one of the industry’s highest-volume manufacturers.

Our products, from battery chargers to power management systems to battery systems, have a tradition of unrivaled quality, reliability, and longevity, even in the most demanding applications and environments. We offer customized products tailored for specific customers and applications, and Lester Electrical customers enjoy unparalleled quality, service, and support.

Engineering Capabilities

The Lester Electrical engineering department designs electrical power conversion and storage products and systems to power recreational, commerical, and industrial electric vehicles. Our engineering department works with electric vehicle and machine manufacturers to develop solutions customized to their exact requirements. We have complete electrical, mechanical, and software development capabilities, which include the following.

• Design engineering
  • Electrical
  • Mechanical
  • Software
• Engineering support
  • Technicians
  • Layout
  • CAD designers
• Manufacturing engineering

Manufacturing Capabilities

• Vertically-integrated manufacturer
• ISO 9001 certified
• 90,000 square foot facility
  • Lincoln, Nebraska
• Electronic assembly per IPC guidelines
  • Surface mount technology (SMT)
• Through hole
• Cable assembly
  • Cutting, stripping, termination
• 20 to 000 (3/0) AWG
• Transformers up to 10 KW
  • Automatic winders for 9 to 22 AWG
• E/I laminations automatic welding
• Sheet metal
  • 33-ton automatic turret presses
• Powder coating
  • Parts up to 34x37 inches
• Electromechanical assembly

Vertically-Integrated Manufacturer
Lester Electrical manufactures products in a 90,000 square foot facility in Lincoln, Nebraska. Our Quality Management System is registered to ISO 9001 standards, and we assemble printed circuit boards per IPC guidelines.

Electronic Assembly
Lester Electrical has the capability to assemble surface mount and through hole circuit boards. Our state of the art pass-through system includes a fully-automatic DEK screen printer, two MyData MY9 placement machines in series, and a Heller reflow oven. This system provides the capability of placing small 0402 parts, BGAs (ball grid arrays), and large fine-pitched QFP parts of 0.5 mm pitch. The MyData system utilizes smart feeder systems to verify that the correct value part is placed.

Through hole assembly is accomplished through high-speed automatic Universal placement equipment including axial, radial, and DIP insertion equipment. These boards are soldered using an Electrovert wave solder machine.

Cable Assembly
We have the capability to handle wire cutting, stripping, and termination for a wide combination of cables and terminations: 20 to 000 (3/0) AWG. Automatic cut and strip machines ensure a quality cable with accurate length and strip dimensions.

Transformers
Lester Electrical can build transformers from 50 W to 10 KW. We have automatic winding capabilities from 9 to 22 AWG and the capability to manually wind up to a 4 AWG wire. We can automatically weld E/I laminations up to 2 1/4 inches. We varnish all transformers and vacuum impregnate to help increase the life of a transformer in the field. This helps to provide a quiet, longer-life transformer.

Sheet Metal
33-ton Finn Power automatic turret presses provide quick and accurate turnkey metal fabrication parts. Two of the presses have automatic right angle shear capabilities. Punching capabilities in material up to 5/16 inch thick is accomplished through an automated tool changer with punches up to 1 1/2 inches in diameter. Forming capabilities are processed through a series of punch presses and brakes. We also can provide secondary operations such as spot welding if needed.

Powder Coating
Our powder coat system processes parts through an aqueous parts washer, powder coat booth, and cure oven. Metal parts up to 34x37 inches can be powder coated for a very durable and long lasting finish in a variety of colors.

Electromechanical Assembly
With several well equipped assembly areas, Lester Electrical can offer electronic and final assembly options to meet your specific needs. With a turnkey facility which includes PCB assembly, sheet metal fabrication, and final assembly, we offer one-stop shopping.