The Custom Battery Assemblies: Benefits and Processes


The Power Source Professionals
Providing power solutions for unique applications


In today's world, there is a growing need for batteries to power various devices, from small portable electronics to large industrial equipment. However, not all applications are the same, and sometimes, off-the-shelf batteries do not meet the specific requirements of a particular device or application. This is when a custom battery assembly is essential.

Custom battery assemblies are tailored power solutions designed to meet the unique power needs of an application. These assemblies are made up of individual battery cells that are configured and connected to meet the specific voltage, current, and capacity requirements of a device or system. 

There are several benefits of using custom battery assemblies. One of the primary advantages is the ability to optimize the power supply for a specific application. This means that the battery can be designed to provide the required voltage, current, and capacity, ensuring that the device operates at optimal performance.

Another benefit of custom battery assemblies is the flexibility in the design. These assemblies can be designed to fit into tight spaces or unusual shapes, making them suitable for applications where space is limited. Additionally, custom battery assemblies can be designed to include safety features, such as overcharge and over-discharge protection, to ensure that the battery operates safely and reliably.

Custom battery assemblies can also provide cost savings over off-the-shelf batteries. By designing the battery to meet the exact requirements of the application, excess capacity or voltage can be eliminated, reducing the overall cost of the battery.

The process of designing and building a custom battery assembly involves several steps.
   1)  Identify the specific power requirements of the application including the required voltage, current, and capacity.
   2)  Select the appropriate battery chemistry and cell configuration.
   3)  Engineer and design the battery which may include a battery management system (BMS).
        - This requires determining the charging and discharging parameters, as well as incorporating safety features.
   4)  Designing the production method to assembly the battery.
        - This involves connecting the cells, installing the BMS (if required).
   5)  Testing the assembly in our Quality Control team.

Whether its a new design, a re-design of an existing battery or if you're looking for a new assembler for your current battery, let StorTronics be your choice!