Custom Battery Pack Design
Custom Battery & Energy Solutions
For over 57 years, Custom Power has designed, developed, and manufactured high-quality, reliable, custom battery packs. We provide battery pack assemblies in all chemistries, optimizing performance and meeting the requirements of clients who need battery solutions for emergency systems, military equipment, aerospace systems, and other applications. Our clients rely on Custom Power to provide them with the competitive edge they need.
Our engineers and technicians and the rest of our skilled staff have over two centuries of combined experience. The breadth of expertise at Custom Power allows us to specialize in the design and manufacturing of lithium-ion battery systems, including in-house circuit and firmware design. Our technical experience and chemistry knowledge ensures the safest and best match for your application.
Contact us to learn how we can provide you with the best battery solution for your application.
Benefits of our Custom Battery Packs
If you need custom-designed battery packs for your medical, aerospace, defense, or industrial applications, Custom Power is your ideal choice. We are one of the largest authorized custom battery assemblers in the country, and domestic and international clients choose us for these benefits:
- Our expert designers: The Custom Power in-house development, engineering, and design teams have worked with some of the top companies in the world, developing circuit design, battery management systems, and complex battery pack assemblies.
- Custom battery solutions tailored to your needs: Our team carefully considers the unique needs of each project so we can create the technologies required for the most demanding and unique requirements.
- High-quality batteries: Our custom batteries offer high efficiency, enhanced safety and an optimized fit. We meet regulatory requirements for UL, CE, IEC, CSA, and other organizations.
- Our knowledge, experience, and partnership: We are part of the Rechargeable Battery Recycling Corporation (RBRC). Our technicians expand their skills with ongoing certification, and the entire Custom Power team is dedicated to continual training to make sure we bring cutting-edge knowledge and expertise to your project. We are your partner in developing custom battery packs that meet and exceed your expectations.
Custom Power provides custom battery design for:
- Primary lithium batteries
- BMS circuitry integration
Lithium-Ion cells (available in both cylindrical and prismatic formats) are offered in designs that can provide high-energy density or high-power options to meet the various demands of OEM products such as medical devices, power tools and drones.
Lithium-polymer cells are offered in many sizes and are available in high-energy as well as high-rate configurations. Offered in prismatic sizes from small to large format, lithium-polymer cells make a great choice for small electronic devices and high-power lightweight drones.
Lithium iron phosphate
Lithium iron phosphate chemistry yields less energy density compared to other Lithium-Ion blends but provides excellent cycle life, high-rate discharge capability, and superior thermal stability. In general, it is a great choice for long-life and remote applications.
Custom Power designs, develops and manufactures custom lithium primary battery packs and assemblies for a wide range of applications. Utilizing advanced mechanical and electronic design techniques, our skilled battery design team will optimize your custom lithium battery packs’ reliability, manufacturability, and safety. This process gives our customers the most dependable, most economical lithium primary battery pack solutions for their unique needs.
Custom Lithium Battery Packs & Assemblies
Lithium is the lightest non-gaseous metal, and its negative potential for battery packs is higher than any other metal. Lithium-chemistry batteries and battery packs have the highest specific energy (energy per unit weight) and energy density (energy per unit volume) of all battery types.
While most lithium cells have open circuit voltages (OCVs) between 2.7 and 3.6 V, most lithium primary cells have a relatively high impedance which generally limits them to low-drain applications. Special high-rate discharge cells are available for certain applications.
Lithium primary batteries often have broad operating temperature ranges, and can continue to function properly at temperatures from -55° to 150°C (-67° to 302°F). Though incineration or other exposure to extremely high temperatures can cause lithium batteries to experience catastrophic failure, other battery types typically react similarly in the same conditions.
Primary lithium battery packs are available in several different chemistries, each with its own set of performance and safety characteristics. Poly (carbon monofluoride) lithium, or (CF)X-Li; manganese dioxide lithium, or MnO2Li; thionyl chloride lithium, or SOCl2Li; and sulfur dioxide lithium, or SO2Li, have all proven to be especially popular and effective.
Custom Lithium-Manganese Dioxide Battery Packs & Assemblies
Manganese dioxide lithium cells are similar to poly (carbon mono-fluoride) cells in energy density, construction, safety, and OCV, but generally provide only about half the service life. However, MnO2Li cells are well-suited to applications requiring relatively high continuous- or pulse-current requirements, as their internal impedance is lower than that of other chemistries.
Manganese Dioxide Lithium Battery Specifications
Manganese dioxide lithium batteries are available in many standard cylindrical and coin sizes.
- Cell voltage: 3.0V (nominal)
- Capacity: 30mAh to 5Ah
- Energy by volume: (230 Wh/kg); 9.0 Wh/in3 (550 Wh/L)
- Energy by weight: dependent on cell configuration; up to 105 Wh/lb.
- Discharge characteristics: Flat (stable voltage) discharge curves
- Shelf life: 10+ years at 20°C (68°F)
- Operating temperature range: -20° to 60°C (-4° to 140°F)
- Sizes: variable
- Applications: general purpose for applications requiring small, high powered batteries, e.g. security transmitters, smoke alarms, cameras and photographic equipment, computer peripherals, communications equipment, personal organizers, memory backup, lights, etc.
Custom Power manufactures custom nickel cadmium battery packs and assemblies. Our battery design team uses the latest mechanical and electronic design tools to optimize the reliability, safety and manufacturability of your custom battery packs. This gives you the most cost effective and dependable nickel cadmium battery pack solution for your specific needs.
Custom Nickel Cadmium Battery Packs & Assemblies
Nickel Cadmium (NiCd) is a well-established chemistry for custom battery packs & assemblies. Although newer battery chemistries have taken the spotlight in recent years, Nickel Cadmium still remains a viable chemistry today for some applications.
Nickel Cadmium Battery Characteristics
Nickel Cadmium batteries have several advantages over other battery chemistries in use today.
- Nickel Cadmiums can take a fast charge, some in as little as 15 minutes and can take a charge at lower temperatures.
- Maintained properly, Nickel Cadmiums are capable of thousands of cycles.
- Nickel Cadmiums can sustain heavy loads.
Nickel metal hydride
Custom Power manufactures custom nickel metal hydride battery packs and assemblies. Our battery design team uses the latest mechanical and electronic design tools to optimize the reliability, safety and manufacturability of your custom battery packs. This gives you the most cost effective and dependable nickel metal hydride battery pack solution for your specific needs. NiMh cells and batteries are generally lower cost than lithium rechargeable cells and batteries and are not as heavily regulated.
Custom Nickel Metal Hydride Battery Packs & Assemblies
Nickel Metal Hydride (NiMH) cells have gained in popularity since the late 1980s. Steady increases in performance and minimal transport regulations have made this chemistry an excellent choice for small, lightweight, portable, and handheld battery packs & battery assemblies applications.
Custom Battery Pack Design & Engineering
As one of the industry’s premier manufacturers of custom battery packs, Custom Power specializes in battery pack design and engineering. We provide our customers with complete energy solutions for their unique applications, from medical to military to industrial and beyond. By working with leading battery manufacturers, we are able to deliver the most dependable and most economical custom battery pack solutions for our clients.
Custom Battery Packs Tailored to Your Needs
With our custom battery pack design and engineering capabilities, Custom Power can design and produce custom portable power systems using a variety of battery cell chemistries, including:
- Lithium Ion
- Lithium Polymer
- Lithium Primary
- Lithium Iron Phosphate
The cell chemistry of all custom battery packs we develop is carefully selected to match the specific requirements of each customer application. We will work with you to create a complete, custom power solution that delivers the performance and reliability you need and fits your size and configuration requirements.
Because we utilize both primary and secondary chemistries, we give our clients access to a wide range of custom battery packs and battery solutions.
Utilizing advanced mechanical and electronic battery design tools and test equipment, as well as extensive custom battery pack design and engineering experience, Custom Power is able to optimize the safety, reliability, and manufacturability of our customers’ batteries.
Custom Battery Design Team
Between our skilled engineers and technicians and our highly knowledgeable sales staff, Custom Power has over 200 years of combined battery design experience. Ongoing training and certification ensures that our assembly technicians are able to consistently produce superior quality custom battery packs, based on the most advanced designs in the industry.
Custom Power's engineering team puts this extensive experience to work designing and manufacturing custom battery packs, battery assemblies, and chargers. From the design and prototyping stages through full production, you can count on Custom Power to deliver the perfect custom energy solution for your application.
Battery Pack Assembly Facility & Equipment
Through our commitment to the continual improvement of our battery manufacturing facility, Custom Power can consistently provide the highest quality products. Through upgrades and augmentation of our manufacturing and test equipment, and ongoing training and certification of our staff, we can meet the demands of our clients and stay ahead of the ever-changing market conditions of our industry.
Rechargeable Battery Packs
Custom Power offers rechargeable battery packs in a variety of chemistries and configurations. We provide innovative, high-performance battery solutions for a broad range of industries and applications.
Our team has the expertise to create custom rechargeable battery packs that meet your unique requirements, drawing on 200-plus years of combined battery design experience. Custom Power will deliver the dependable, cost-effective rechargeable battery packs your application requires.
Rechargeable Lithium Batteries
Rechargeable lithium batteries are popular for a wide array of applications. These battery packs provide excellent energy density, hold their charge for long periods when not in use, and do not experience “memory effect” in charging. They can be manufactured in myriad shapes and sizes to fit the devices they power, and are much lighter than comparable rechargeable battery packs that utilize different chemistries.
Rechargeable lithium-ion battery packs are available in a number of different chemistries, each with unique performance, cost, and safety characteristics. Contact Custom Power for assistance in selecting the most effective chemistry for your specific application.
Rechargeable Lithium Ion Battery Packs
Rechargeable lithium-ion (Li-ion) rechargeable battery packs continue to grow in popularity thanks to their greater energy density—up to twice that of nickel- and lead-based chemistries—and low self-discharge rates, as well as ever-improving technologies that continue to make them safer and less expensive than earlier lithium battery types. Rechargeable lithium ion batteries are commonly used in a broad spectrum of applications, including:
- Military/aerospace equipment
- Medical devices
- Asset tracking
- and many others
Other Rechargeable Battery Pack Chemistries
Lithium Polymer Rechargeable Battery Packs
Lithium polymer rechargeable battery technology is similar to Li-ion in many ways. The key difference between the two is their packaging—instead of the steel or aluminum cans used for Li-ion batteries, lithium polymer cells are typically housed in foil-like pouches. This allows for packaging flexibility, and can provide lower costs and safer operation.
Lithium polymer cell technology is constantly improving, as manufacturers introduce ever smaller, lighter, and more powerful cells. Lithium polymer rechargeable battery packs are available in different, custom-tailored configurations that can deliver longer run times or higher discharge rates. Cells as thin as a credit card are possible. Common applications include:
- Small one- or two-cell consumer electronics
- and many others
Contact Custom Power to discuss your custom battery pack requirements.
Note: Due to lithium’s inherent volatility, and lithium polymer’s generally high energy density, every lithium-ion and polymer battery and cell requires a battery management circuit to control and monitor its upper and lower voltage thresholds during charge and discharge. Custom Power designs and thoroughly tests the battery management system of each lithium-ion and polymer battery pack we assemble to guarantee optimum safety and performance.
Sealed Lead Acid Rechargeable Battery Packs
Sealed lead acid batteries (SLA batteries) are available at low initial cost and are easy to maintain, making them ideal for a wide range of rechargeable battery applications. Unlike other chemistries, such as lithium ion or lithium polymer, SLA batteries don’t require sophisticated battery management circuitry and are not as heavily regulated for transportation.
SLAs have the lowest energy density of any rechargeable battery chemistry. In instances where size and weight aren’t critical factors, and where costs must be kept to a minimum, sealed lead acid rechargeable battery packs are an ideal solution.
SLA batteries are also uniquely suited to stationary and standby applications, such as uninterruptible power supplies and emergency lighting, where reliability and long working life are a must. And, because SLA cells are predictable and easy to maintain, they’re commonly used for medical devices and electric wheelchairs requiring high power.
A popular SLA variation is “pure lead” technology, such as EnerSys Cyclon. Pure lead batteries are capable of faster charging and perform well at lower temperatures. These batteries also exhibit much better charge retention and recovery after long periods of storage (1-2 years) and longer calendar life (5-8 years). Pure lead SLA rechargeable battery packs are popular for medical and defense applications.
Nickel Cadmium Rechargeable Battery Packs
Nickel cadmium (NiCd) is one of the oldest battery chemistries. Despite the development of numerous new chemistries in recent years, nickel cadmium remains a popular and reliable technology for rechargeable battery packs. When properly maintained, NiCd batteries can last for thousands of cycles.
Nickel cadmium batteries used in portable applications are usually either spiral wound cylindrical cells or button cells. Larger plate NiCd wet cell batteries are often used in aircrafts and long-term stationary applications.
Nickel Metal Hydride Rechargeable Battery Packs
Steady increases in nickel metal hydride (NiMH) cell performance have made this chemistry a popular choice for small, lightweight, portable electronic applications. Unlike lithium ion, lithium polymer NiMH batteries do not require sophisticated battery management circuitry to maintain their performance. Additionally, NiMH rechargeable battery packs are not as heavily regulated for transport as lithium cells.
NiMH batteries provide 30-50% more energy capacity than same-size NiCd cells. They are also less prone to the “memory effect” that can hamper NiCd batteries. And, compared to lithium ion and lithium polymer rechargeable battery packs, NiMH cells are a far more economical choice.
Battery Types and Considerations
The critical considerations when selecting the right battery or custom battery packs are:
- Rechargeable or non-rechargeable?
- Nominal, minimum and maximum voltage?
- Initial, average, and maximum discharge current?
- Continuous or intermittent operation?
- If intermittent, the amplitude and duration of minimum and peak current drains?
- Required service life?
- Operating-temperature range?
- A worst-case analysis, including highest expected current at lowest expected temperature and permitted Voltage-rise time to minimum voltage?
- Storage duration and condition?
Battery Chemistries to Consider:
Lithium Ion (Li-Ion) & Lithium Polymer: May have twice the energy density of NiCd, can be capable of high discharge currents, and relatively low self-discharge. Often used for medical, military, industrial, consumer electronics.
Lithium Iron Phosphate (LiFePO4): superior thermal and chemical stability, can handle higher temperatures without significant damage, higher rate discharge, longer cycle life, but lower voltage and energy density than other Li-ion chemistries. Often used for electronic vehicles, power tools, medical and military applications.
Nickel Cadmium (NiCd): fast charge, can take a charge at lower temperature, capable of thousands of cycles, competitively priced, limited size since they have been banned in some regions due to environmental concerns. Often used in medical and industrial equipment, test and measurement instruments, and other applications.
Nickel Metal Hydride (NiMH): No recycling issues, more capacity and no memory effect as NiCd, competitively priced, but can lose charge faster than NiCd. They are often used for small, lightweight, portable, and handheld battery packs.
Sealed Lead Acid (SLA): Low initial cost, easy maintenance, low energy density, good charge retention, predictable discharge. Often used for medical devices, uninterruptable power supplies, and emergency lighting.
Lithium Primary: Non–Rechargeable: Highest energy unit per weight, mostly limited for low drain applications, can operate in a wide temperature range. Often used for photographic and electronic applications, security transmitters, smoke alarms, communications equipment, utility meters, scientific instruments, and other applications.
Alkaline: Non–Rechargeable: Better performance at low temperatures than Carbon Zinc/Zinc Chloride, low cost, longer shelf life and leakage resistance than carbon zinc. Often used for toys, flashlights and radios.
Carbon Zinc/Zinc Chloride: Non–Rechargeable: Low cost, limited shelf life, susceptible to leakage. Often used in radios, toys, and flashlights.
Silver Oxide: Non–Rechargeable: Small size, stable discharge voltage, good shelf life, able to operate over a wide temperature range. Often used for calculators and watches.
Zinc-Air: Non–Rechargeable: Small size, large capacity, quick start-up, stable voltage, light weight. Often used for pagers, hearing aids, and other small medical equipment.
Contact an Expert
Feel free to contact us by telephone at (877) 896-0721. You can also email us at firstname.lastname@example.org or fill out our online form to get a quote or discuss your next battery project.
Our solution development team is standing by to help.