How to Order a Customised Battery Pack

A Guide To Orderings A Custom Battery Pack

Battery solutions are fast becoming crucial for powering applications across various industries. With the complexity and diversity of batteries available in the market today, it is advisable to seek the guidance of an experienced battery specialist when planning and selecting the optimal battery solution. In this article, we will delve into what application manufacturers should understand when choosing a battery partner and ordering a tailored battery pack.

A Customised Battery Pack vs. a Standard Battery Pack

Sometimes, a standard battery pack can be used, but often, the application has requirements (physical dimensions, operational temperature, safety standards, cycle life, etc.) that cannot be met with an existing battery, and a customised battery is required to avoid unwanted compromises.

A properly designed customised battery solution considers the total battery lifecycle and the Total Cost of Ownership (TCO). The design process is transparent and flexible, and most importantly, it ensures the safety of use throughout the battery’s lifetime.

This article will explore what you should know when ordering a customised battery, detailing the steps involved, key considerations, and the benefits of partnering with a professional supplier.

Step-by-Step Guide to Ordering Your Custom Battery

Step 1: Define Your Requirements

The first step in ordering a customised battery pack is defining your specific requirements. This involves understanding the operational context of the device or application and detailing your needs. Consider the following:

  • Device specifications: What is the battery needed for? What are its critical functions? What is its lifetime expectancy?
  • Operational environment: Where and under what conditions will the device operate?What are the connector and interface requirements? What is the charging concept?
  • Regulatory compliance: Are there specific standards or certifications needed?

Step 2: Early Engagement with your Battery Supplier

Once you have a clear understanding of your needs, the next step is to engage with your battery supplier early in the design process. Early engagement ensures timely delivery and that your battery solution is seamlessly integrated into your device without compromising design or performance.

  • Consultation: Discuss your specifications with your supplier’s battery experts to explore various battery chemistries and configurations.
  • Collaborative design: Work closely with your supplier’s engineers to tailor a battery solution that meets your specific requirements.

Step 3: Design and Development

An experienced battery manufacturer will design and develop a battery solution based on the specifications, carefully considering every detail to provide safety, durability, optimal weight, and the desired shape.

  • Battery type and chemistry: The supplier will propose the most suitable battery type based on your device’s energy consumption and operational requirements. As battery technologies evolve continuously, it is best to trust your supplier’s expertise and recommendations.
  • Sourcing and Tooling: These steps may take some time and affect the battery’s delivery time. Therefore, sourcing and tooling should be planned early in the process and with care.
  • Scheduling: It is important that the scheduling is planned together with the supplier, taking into consideration the application’s schedule and the time needed to design, test, certify, produce and ship.
Customised Battery Packs 1

Step 4: Validation and Testing

If the battery solution fails, the application cannot be used. Therefore, one must ensure the battery solution fits its purpose in all use cases and circumstances. Select a partner who can perform all the required prototyping and testing.

  • Prototyping: Often, a prototype is needed to test that the planned design meets all the requirements.
  • Testing according to standards: Find out what standards your battery should be tested according to.
  • Factory Acceptance Testing (FAT): FAT involves a series of tests and inspections to ensure that the battery meets the specified requirements, design criteria, and functionality.

Step 5: Certification and Compliance

Your battery supplier can assist with defining and obtaining the needed certifications, ensuring that your battery complies with local and international regulations. Note that certifications are market-specific: CE in Europe, UL in the US, etc.

  • Performance certifications: Various IEC and UL certificates regarding capacity, charge/discharge efficiency, lifecycle, and reliability under electrical and mechanical stress, etc.
  • Safety certifications: Fire safety, safety under misuse, electrical, mechanical, and environmental stress to ensure safety, etc.
  • Transportation certifications: UN 38.3 for transporting lithium and lithium-ion batteries, IATA for air transport, ADR for road transport, etc.

Step 6: Production and Delivery

Ensure you select a battery supplier who can produce batteries within the desired schedule and volume and professionally manage the logistics.

  • Certified manufacturing plants: Ensure manufacturing plants have all the required ISO certifications, ensuring desired quality, occupational health & safety, and environmental management systems.
  • Technical competence: Choose a battery supplier that uses modern technologies, such as laser welding, ultrasonic welding, and resistance welding, to produce high-quality batteries.
  • Global logistics: Select certified logistics with efficient distribution channels that meet your delivery timelines and global needs.

Step 7: Post-Delivery Support

Evaluate the level of support you will need after delivery and choose a partner who can provide it. Your supplier can guide you on the safe use of your customised battery pack in different situations.

  • Lifetime support: Agree with your supplier on a suitable service level of technical support covering maintenance, upgrades, and troubleshooting.

Step 8: Second life and recycling

When industrial batteries reach the end of their useful life, they must be recycled according to local legislation. The producer of a battery or a product containing a battery has the producer’s responsibility to take care of the recycling.

  • Registered producers: Ensure you purchase batteries only from registered producers.
  • Sustainability: Assess the environmental impact of your product and ensure that the battery complies with local legislation.
  • EU Battery Regulation: The EU Battery Regulation requires the company importing the battery into an EU country (even from another EU country) to meet its requirements. Therefore, selecting a reliable local battery supplier can be a better option than importing batteries yourself.

Step 9: Ensuring Future-Proof Battery Solutions

An often overlooked but critical aspect of ordering a custom battery is ensuring the solution is future-proof. This means selecting a supplier capable of providing consistent, reliable battery solutions over the product’s expected lifespan, even as market conditions and technologies evolve.

  • Reliable cell supply: Ensure your supplier has continuous access to the necessary cell types even as technologies evolve.
  • Sustained product viability: By ensuring that your battery solution can adapt to future technological changes, you maintain the viability and competitiveness of your product.
  • Compliance and performance: Future-proof battery solutions help maintain compliance with new regulations and standards, ensuring that your product continues to meet market demands without compromising performance.
How To Order Customised Battery Packs

Why Choose Celltech for Your Custom Battery Needs?

Our vast network of suppliers and in-house production ensure the optimal solution for your application.

Quality Management Systems:

Our manufacturing plants are certified according to ISO9001, ISO45001, ISO 13485 and ISO14001.

Certified Sustainability:

To demonstrate our dedication to sustainability, we have EcoVadis certificates for our factories in Finland and Germany.

Extensive Testing:

We exceed standard testing requirements to ensure peak performance.

Supply Chain Management:

We emphasise a strong supply chain to ensure stable quality and timely delivery, prioritising manufacturers that use environmentally sustainable materials. We have reliable, audited cell and component suppliers with long partnerships.

Future-Proof Solutions:

Our approach to future-proofing involves agile product development and maintaining strong, long-term relationships with reliable cell suppliers to ensure cell availability even when technologies evolve.

Battery Design Expertise:

Our team designs comprehensive solutions, including advanced Battery Management Systems (BMS), tailored to the specific needs of each application.

Continuous Innovation:

Our commitment to exploring new chemistries and technologies drives us forward.

Scalability:

We have scalable manufacturing plants in Finland, Germany, Bulgaria, the United Kingdom and China.

Expertise:

We are experts in battery production, from the mass production of medical battery packs to specialised weather-resistant batteries.

Modern Technologies:

We use various advanced technologies in our manufacturing plants, such as laser, resistance, and ultrasonic welding, as well as wire bonding. Furthermore, we use a 100% computerised final check to guarantee consistent and high quality.

Local Support:

Celltech operates in Germany, Sweden, Norway, Denmark, Finland, Bulgaria, China, Hong Kong and the United Kingdom providing local support for the entire battery lifecycle.

Celltech Lifecycle Approach:

At Celltech, we always consider the entire lifecycle of our battery solutions, from design to recycling. Celltech Lifecycle is our operational model.

Ordering a customised battery from Celltech is a strategic decision that promises not only a tailored solution but also a partnership with a leader in battery technology. By following the outlined steps—from defining your requirements to post-delivery support—you can ensure that your custom battery enhances the performance and reliability of your device. With Celltech, you gain more than just a battery supplier; you gain a dedicated partner in powering your technological innovations.

Read more about custom battery packs.

Contact us for more information or to start your custom battery project!