Nominal Voltage
Defined against the device load, runtime target and operating limits.
Custom cylindrical Li-ion battery pack engineering
Custom Li-ion Battery Packs
We design and manufacture custom Li-ion battery packs using 18650, 21700 and other approved cells. Voltage, capacity, discharge current, BMS, wiring, connectors and enclosure are matched to your OEM product.
- Nominal voltage
- 3.6V / 3.7V to 72V
- Typical capacity
- 2Ah to 200Ah, project dependent
- Cell formats
- 18650, 21700 & approved alternatives
Product details & applications
Custom Li-ion Battery Packs: Details and Application Examples
The cell platform, bus structure, protection electronics and thermal sensing are selected as one approved assembly.
Voltage, current, runtime, connector and enclosure requirements are evaluated against the real device duty cycle.
Product overview
Custom Li-ion Battery Packs for OEM Product Development
A reliable Li-ion battery pack starts with the load profile, available space and charging system. We use those inputs to select the cell format, series-parallel layout, protection, wiring and enclosure for the complete OEM assembly.
Key Features
- Application-led selection of energy or power cells
- 1S to multi-series and series-parallel pack architecture
- 18650 and 21700 cylindrical Li-ion formats
- PCM or smart BMS integration with cell balancing
- Custom wire harnesses, connectors and communication
- Heat-shrink, molded plastic or metal enclosure options
- Thermal sensing, insulation and mechanical retention design
- Prototype, pilot and flexible OEM / ODM production
Common customization ranges
Common Custom Li-ion Battery Packs Design Choices
These ranges help start the discussion; they are not fixed stock models. We review dimensions, capacity, load and interfaces together before confirming a design.
- Common nominal voltage classes
- 3.6/3.7V7.2/7.4V10.8/11.1V14.4/14.8V18/18.5V21.6/22.2V24V class36V48V60V72V class
- Cell and construction options
- 1865021700Energy cellPower cellHeat-shrink packMolded housingMetal enclosure
- Control and interface options
- Basic PCMBalancing BMSFuel gaugeNTC sensingUART / SMBusCAN / RS485Custom harness
Customization Capabilities
Customization Options for Custom Li-ion Battery Packs
Voltage, capacity, dimensions, protection and interfaces affect one another. We review them as one system, then confirm the final design through drawings, specifications and samples.
Usable Capacity
Defined against the device load, runtime target and operating limits.
Continuous Current
Defined against the device load, runtime target and operating limits.
Peak Current
Defined against the device load, runtime target and operating limits.
18650 / 21700 Cell
Selected and arranged to balance performance, size, service life and manufacturability.
Series / Parallel Layout
Selected and arranged to balance performance, size, service life and manufacturability.
PCM / Smart BMS
Protection, sensing and control functions coordinated with the approved system architecture.
NTC Thermistor
Protection, sensing and control functions coordinated with the approved system architecture.
Wire Gauge & Length
Interface type, position and electrical rating matched to the host product.
Connector System
Interface type, position and electrical rating matched to the host product.
Communication Protocol
Interface type, position and electrical rating matched to the host product.
Heat-shrink / Housing
Mechanical details reviewed against available space, assembly method and product handling.
Mounting Features
Mechanical details reviewed against available space, assembly method and product handling.
Label & Packaging
Material, finish and presentation options confirmed for the product and supply program.
Voltage architecture
Custom Li-ion Battery Packs Configuration Examples
These examples support early engineering discussions. Cell voltage and final pack limits follow the approved cell, protection and system specification.
3.6V / 3.7V Nominal
Compact electronics, lighting and portable devices
7.2V / 7.4V Nominal
Monitoring devices, instruments and smart hardware
10.8V / 11.1V Nominal
Portable equipment, security and industrial electronics
14.4V / 14.8V Nominal
Robotics, instruments and higher-power portable products
21.6V / 22.2V to 25.2V / 25.9V
Mobility, automation and application-specific equipment
36V to 72V Class
Higher-voltage OEM systems, subject to engineering review
Cells & Construction Materials
Custom Li-ion Battery Packs Cells and Construction
Cell chemistry is only one part of the solution. Interconnects, insulation, sensing and enclosure materials must work together as an approved assembly.
| Cell formats | Cylindrical 18650 and 21700 cells; other formats reviewed when the enclosure or load requires them. |
|---|---|
| Cathode systems | NMC, NCA or LCO-based Li-ion cells may be evaluated according to energy density, power, cycle life, availability and cost. |
| Cell enclosure | Steel-can cylindrical cells with insulating rings, sleeves and spacing selected for the approved construction. |
| Interconnection | Nickel strip, nickel-plated steel or engineered busbar construction selected according to current and pack architecture. |
| Insulation | Fish paper, PET barriers, cell holders, foam and heat-resistant insulating materials applied as required by the design. |
| Outer packaging | PVC/PET heat shrink, ABS/PC molded housing or metal enclosure, with brackets and sealing targets reviewed per project. |
Technical Specifications
Technical Specifications: Custom Li-ion Battery Packs
These values provide a clear starting point for product selection and engineering review. Final electrical, mechanical, environmental and compliance values are confirmed for the approved design.
- Product type
- Rechargeable cylindrical lithium-ion battery pack
- Nominal voltage / voltage range
- 3.6/3.7V, 7.2/7.4V, 10.8/11.1V, 14.4/14.8V, 18/18.5V, 21.6/22.2V, 24V-class, 36V, 48V, 60V and 72V-class
- Capacity / energy / power
- 2Ah to 200Ah for feasibility discussion; final range depends on cell, voltage, current, dimensions and weight
- Dimensions
- Custom to the approved cell platform, capacity target, protection, tolerances and available enclosure space.
- Construction / format
- 18650, 21700 or another approved cylindrical format
- Electrical output
- Common project discussions range from approximately 2A to 60A; higher or lower requirements require cell, BMS and thermal validation
- Protection / control
- Overcharge, over-discharge, over-current, short-circuit and temperature protection; balancing and secondary safeguards where required
- Cable & connector
- Custom wire gauge, length, exit direction, connector, polarity and pinout where applicable.
- Operating environment
- Cell- and design-specific; a commonly discussed discharge window is around -20°C to 60°C, while charging limits are normally narrower
- Customization
- Nominal voltage, Usable capacity, Continuous current, Peak current, 18650 / 21700 cell, Series / parallel layout, PCM / smart BMS, NTC thermistor, Wire gauge & length, Connector system, plus additional project-specific options
- Production & compliance
- UN 38.3 transport testing, IEC 62133, UL, CE, RoHS, REACH or market-specific documents are evaluated for the exact project; availability is not assumed
Need another value? Send the device voltage, load profile, runtime target, maximum dimensions, charging method and operating environment for an engineering review.
Applications
Typical Applications for Custom Li-ion Battery Packs
IoT & Monitoring Equipment
Evaluated against the device load, available space, operating environment and production requirements.
GPS & Asset Trackers
Evaluated against the device load, available space, operating environment and production requirements.
Security Devices
Evaluated against the device load, available space, operating environment and production requirements.
Robotics & Automation
Evaluated against the device load, available space, operating environment and production requirements.
Portable Instruments
Evaluated against the device load, available space, operating environment and production requirements.
Medical and Wellness Devices
Evaluated against the device load, available space, operating environment and production requirements.
Lighting & Emergency Equipment
Evaluated against the device load, available space, operating environment and production requirements.
Smart Consumer Hardware
Evaluated against the device load, available space, operating environment and production requirements.
Mobility Equipment
Evaluated against the device load, available space, operating environment and production requirements.
Backup and Communication Devices
Evaluated against the device load, available space, operating environment and production requirements.
Engineering support
From Custom Li-ion Battery Packs Requirements to Production
Each step confirms the technical details needed for a working prototype and repeatable OEM production.
- 01
Requirement Review
Application and targets
- 02
Electrical Evaluation
Load and charging
- 03
Solution Design
Architecture and interfaces
- 04
Prototype Development
Samples for evaluation
- 05
Testing & Validation
Performance and fit
- 06
Pilot Production
Process confirmation
- 07
Mass Production
Inspection and delivery
FAQ
Common Questions About Custom Li-ion Battery Packs
Is a custom lithium battery pack the same as a custom Li-ion battery pack?
For this product series, yes. “Custom lithium battery pack” is the broader buyer-facing term, while the main construction described here uses rechargeable cylindrical Li-ion cells such as 18650 or 21700. Small pouch LiPo batteries and 12V/24V LiFePO4 replacement batteries remain separate Meanwatt product series.
What information is needed to start?
Share the device input voltage, continuous and peak current, runtime target, maximum battery envelope, charging method, operating environment, connector, communication needs, target market and estimated quantity.
How are voltage and capacity configured?
Cells connected in series increase pack voltage, while parallel groups increase ampere-hour capacity and current capability. The final series-parallel architecture is checked against the load, charger, available space, thermal conditions and protection strategy.
Which cell material should we choose?
NMC, NCA and LCO-based Li-ion cells have different energy, power, cycle-life, availability and cost profiles. We select from approved cells only after the project priorities and operating conditions are understood.
Can the pack include a PCM or smart BMS?
Yes. Depending on complexity, the pack can use basic protection or a BMS with balancing, fuel gauging, data communication and temperature control. Functions are matched to the cell count, charger, load and host device.
Can Meanwatt develop prototypes?
Yes. Prototype and pilot stages can confirm electrical behavior, runtime, mechanical fit, connector pinout, thermal response and assembly details before volume production.
Are certifications automatically included?
No. Test reports and certification scope depend on the exact cell, pack design, target market and transport route. Required standards should be identified during project review and confirmed in writing.
Can you copy an existing battery pack?
An existing sample can help define dimensions, voltage, connector and interface requirements, but the new design must still be evaluated for cell availability, safety, intellectual-property considerations and system compatibility.
Faster engineering review
Send the Details That Define Your Application
- Device and use environment
- Voltage, load and runtime
- Maximum dimensions
- Charging method
- Connector or interface
- Prototype and annual quantity
Start a project
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