Epec's Blog | Electronics Manufacturing Solutions

In the realm of custom battery design, two critical parameters stand out: sizing and the C rating. These aspects are fundamental to the performance, longevity, and safety of battery packs, especially in applications demanding specific power requirements and space constraints.

Quality and performance are key considerations during custom battery pack manufacturing. If these factors are overlooked, potential battery issues and low-performing packs may enter the market. They could cause malfunctions and damage to devices, or not offer enough power for devices to perform.

Applications may require custom battery packs when off-the-shelf packs cannot meet their requirements. The battery packs may need to use specific materials or have certain power, charge, or safety feature requirements.

Whether using lithium-ion, nickel-based, or lead acid rechargeable batteries, you want them to last for as long as possible with your devices. Constantly buying new rechargeable batteries is not cost-effective to your budget and may lead to using your devices less.

When powering electronics, toys, and other devices, they may rely on rechargeable batteries to operate. Rechargeable batteries can be used repeatedly to power devices due to their ability to connect to a portable charger or be charged within the connected device. Depending on the battery chemistry, a rechargeable battery may be recharged for 500 cycles to 1,000 cycles before reaching its end of life.

Lithium batteries are used in the majority of the high-powered devices used today. From vehicles to cell phones, these batteries come in a range of sizes, watt-hours, chemistry, and volume.

Battery packs contain a multitude of cells that provide the power to the electrical load of a device. Battery chemistries such as lithium-ion can become unstable due to a number of factors. This instability can cause thermal runaway which could lead to an explosion or fire.

When deciding on which battery packs to purchase for applications, one of the factors that customers look at is the manufacturing cost. On average, prices for lithium batteries ranged from about $132 per kWh in 2021 as electric vehicle battery packs in 2022 averaged $153 per kWh. While these prices are lower than back in 2008 ($1,355 kWh), lithium batteries have continually been the most expensive of battery chemistries.

Hazardous environments consist of work areas that may experience elevated levels of corrosion, extreme temperature variations, high pressure, flammable substances, or explosive conditions. Devices operating on battery power need special design requirements to prevent the battery pack from becoming damaged due to these hazardous materials.

New technologies, raw materials, and battery manufacturing have paved the way for new trends in custom battery pack designs. Many of these trends focus on making improvements to the battery's capacity and safety, while others redefine the testing standards implemented to ensure battery packs and chargers function optimally for consumers.