Developing a custom battery pack involves more than designing the final product. The process moves through a series of development stages that help ensure the battery pack meets the application's technical, performance, safety, and production requirements.
The overall timeline can vary based on the complexity of the application, battery chemistry, regulatory requirements, customer testing needs, and production objectives. In many cases, development can range from approximately 4 to 12 weeks depending on the complexity of the design. Lithium battery pack programs, customer product-level testing, and certification activities can extend the overall schedule.
Understanding the major phases before development begins helps establish expectations and supports more effective project planning.
The Battery Pack Development Process
Epec's custom battery pack development process follows a structured progression from concept through production. Each phase builds upon the work completed in earlier stages and helps reduce risk before manufacturing begins.
The development process includes:
- Battery Pack Application Review
- Scope Development
- Scope Refinement
- Development Process
- Prototypes
- Production for non-lithium battery packs
- Regulatory review for lithium battery packs
- Production for lithium battery packs
- UL Certification
Custom Battery Pack Development Timeline Diagram
Beginning with the Application Review
The process starts with a review of the battery pack application. This stage establishes the foundation for the project and helps define the requirements that will influence subsequent development activities.
During the application review, Epec evaluates how the battery pack will be used within the device and the environmental conditions it will experience. This includes reviewing factors such as device use, environmental exposure, operating conditions, and the intended application requirements.
Because all later design and production decisions are tied to application requirements, this initial evaluation plays an important role in the overall development timeline. A clear understanding of how the battery pack will function in the end product helps guide decisions related to design, testing, validation, and production planning.
Defining and Refining Project Scope
After the application review, the project moves into scope development and scope refinement.
These stages focus on reviewing the battery requirement details and clarifying the project requirements before engineering work progresses further. This may include evaluating electrical requirements, mechanical constraints, performance expectations, packaging needs, and other application-specific design considerations.
As requirements become more clearly defined, the development approach can be refined to align with the intended application and production objectives. Refining the project scope before development progresses further helps create a more structured transition into engineering, prototype builds, and production planning.
Development and Prototype Phases
Following scope refinement, the project enters the development process and prototype stages.
During the development phase, engineering work may include printed circuit board assembly layout and bill of materials development for the battery management system. These activities help define the electrical architecture, component requirements, and design details needed to support the battery pack's performance and safety requirements.
Prototype builds provide an opportunity to evaluate the design before full production begins. These prototypes typically consist of actual battery samples that reflect the intended design. Customers can then test the samples within the product or application to confirm that the design meets the required performance and functional expectations.
The prototype phase also serves as an important milestone between development activities and production planning. Readiness for production is typically determined after customer testing confirms the design and final customer approval has been received.
Production Paths for Lithium and Non-Lithium Battery Packs
The production path differs depending on the battery chemistry involved.
For non-lithium battery packs, production typically follows the development and prototype phases once the design has been confirmed and approved.
Lithium battery pack projects typically require additional regulatory activities before production. As a result, the process includes dedicated regulatory and certification stages that can affect the overall project timeline. UN38.3 testing is a mandatory requirement for lithium battery programs and must be considered during project planning.
Because of these additional requirements, lithium battery pack development may take longer than comparable non-lithium projects. Customer product-level testing, field-level testing, and certification requirements are among the most common factors that can extend development schedules.
Regulatory Requirements and UL Certification
For lithium battery pack projects, regulatory activities and UL certification are identified as dedicated phases within the development timeline.
UN38.3 testing is a mandatory regulatory requirement for lithium battery packs. Depending on the application and project requirements, commonly applicable standards may also include UL 1642, UL 2054, and IEC 62133-2.
These steps help support compliance and certification requirements before production proceeds. The inclusion of regulatory review and certification activities is one of the primary distinctions between lithium and non-lithium battery pack development programs.
When certification requirements apply, they should be considered as part of the overall project schedule from the beginning of development. UL certification, in particular, can be one of the factors that extends the development timeline for lithium battery pack projects.
Customer Testing, Approvals, and Production Readiness
Customer participation is an important part of the battery pack development process. Before samples are produced, customers typically review and approve proof drawings to confirm that the design aligns with the application requirements.
Once prototype samples are delivered, customers perform product-level and field-level testing to confirm the design within the intended application. This testing helps verify that the battery pack performs as expected in the customer’s device and operating environment.
Feedback from customer testing may result in design refinements before production approval is granted. Manufacturing readiness is generally achieved once customer testing is complete, required approvals have been received, and the customer has approved the battery pack for production.
Planning for a Successful Development Program
Battery pack development progresses through a series of coordinated stages, from application review and scope definition to engineering, prototyping, certification, and production.
While the duration of each project will vary based on the application and battery chemistry, understanding the sequence of development activities helps establish expectations and improve planning throughout the program. For lithium-based designs in particular, regulatory review, UN38.3 testing, and UL certification can become significant contributors to the overall timeline and should be considered early in the development process.
Customer approvals, product-level testing, field-level validation, and certification requirements should also be built into the schedule from the beginning. These steps help confirm that the battery pack meets the needs of the final application before moving into production.
Summary
Epec’s custom battery pack development process is designed to take a project from concept to full production through a structured series of stages. Each phase, from the initial application review to final production and certification, helps ensure that the pack meets the technical, safety, and performance requirements of the application.
The process begins with a review of the device use, environmental exposure, and application requirements. It then moves through scope development, scope refinement, engineering, prototype samples, customer testing, and production readiness review. For lithium battery pack programs, mandatory UN38.3 testing and applicable certifications such as UL 1642, UL 2054, and IEC 62133-2 may also be required.
Timelines can vary depending on design complexity, chemistry type, customer testing requirements, and regulatory needs. In many cases, development ranges from approximately 4 to 12 weeks, although lithium-based designs, UL certification, customer product-level testing, and field-level validation can extend the overall timeline.
By understanding each phase in advance, customers can better prepare for development, provide required approvals at key milestones, and support smoother collaboration throughout the project.
Key Takeaways
- Structured Process: Epec follows a defined sequence that includes application review, scope development, prototyping, and production to maintain quality and consistency.
- Application Review Is Critical: The process begins with evaluating technical and environmental requirements to guide all subsequent design decisions.
- Timelines Vary by Chemistry: Lithium battery projects require additional regulatory testing and UL certification, extending development time compared to non-lithium designs.
- Prototyping Refines Performance: Building and testing prototypes allows engineers to verify performance and safety before committing to full-scale production.
- Customer Preparation Is Key: Understanding the development timeline and milestones helps ensure smoother coordination, faster approvals, and efficient project completion.
