Epec's Blog | Electronics Manufacturing Solutions

Battery power constantly runs applications on a daily basis to perform a wide variety of functions. Yet, there will be certain instances where battery packs will be stored for short-term and long-term periods. This situation may occur due to infrequent use of the equipment or when storing extra battery packs.

Battery cells generate heat during normal operation. Charging, discharging, and short-circuit conditions all produce heat within the cell as chemical reactions occur to provide stored electrical energy.

Developing a custom battery pack requires balancing electrical, mechanical, and chemical considerations while ensuring the final design performs reliably in its intended application. Beyond selecting a cell chemistry, engineers must understand how the battery pack will behave under different operating and environmental conditions, including its shelf life, charge and discharge characteristics, thermal behavior, and potential safety risks.

Consumers use battery packs for devices used in diverse environments. While the ideal device would experience cool temperatures without drastic temperature changes and be free from corrosion, chemicals, water, shocks, and vibrations, this setup is not always the case. Some devices used in chemical manufacturing processes may experience chemical exposure. Other devices used outdoors may have to deal with harsh temperatures and an abundance of moisture.

The appeal of lithium-based batteries for products has grown immensely. They provide high amounts of power while being light enough for portable devices. However, the battery chemistry is considered unstable, as it requires a battery management system to monitor the pack's temperatures, State of Health (SoH), State of Charge (SoC), and other factors. If the battery should experience a short or thermal runaway, it could cause the pack to catch fire or explode.

Designing a custom battery pack for your application requires figuring out the power specifications. Yet there are several other considerations that dictate the type of battery chemistry to use. In addition to the current, capacity (amp-hours), size requirements, cell configuration, and the number of cells for the battery pack within the application, the voltage must also be determined.

Manufacturing custom battery packs requires comprehensive input from the customer. A customer offers details regarding the application, the power requirements of the battery, and the type of shelf life for the battery pack. The customer also expects battery testing to occur at the end of production to ensure quality and that the battery will work for the application.

Custom battery pack development costs are driven by a combination of technical and regulatory decisions, including battery chemistry, cell count, enclosure design, smart battery functionality, and certification requirements. Understanding these factors early helps balance performance, longevity, and budget while avoiding unnecessary development expenses.

Lithium-ion and lithium iron phosphate (LiFePO4) are the two most widely used lithium-based chemistries in custom battery packs for portable devices and high-power applications. Lithium-ion delivers higher energy density for compact, high-speed electronics, while LiFePO4 emphasizes safety, thermal stability, and extended cycle life. Selecting the correct chemistry directly impacts performance, lifecycle, safety requirements, and regulatory compliance.

It is common to explore different power supply options when designing your applications. However, one that often gets neglected is the differences between the types of battery cells in your portable applications. There are a lot of similarities between battery cells, but also very many differences that make certain cells more efficient than others when it comes to application.