Custom Battery Manufacturing
Custom Battery Packs
AceOn is the leading battery pack manufacturer in the UK, with a proven track record of delivering custom battery pack solutions to customers within numerous key sectors.
We create customised solutions to satisfy the needs and budget of your business, incorporating specific designs and the highest safety standards to ensure your company's needs are met.
In-House Manufacturing: Our battery pack manufacture process is handled by an in-house team of mechanical and electronics engineers, who customise and assemble customer orders from our factory in Telford, England.
We take on projects of all sizes, both big and small, and our team is skilled and qualified to create custom battery packs with the perfect chemistry for your application or use case.
Precision battery cell manufacturing and quality control
Proven Track Record
32+
Years Experience
1,870+
Satisfied Clients
2.3M+
Battery Packs Delivered
Educational Guide
What are Custom Battery Packs?
Custom battery packs are solutions created precisely for the needs and power requirements of your business. They're in contrast to standard battery packs, which are pre-designed and readily available.
The characteristics and benefits of custom battery packs include:
Bespoke design
Every pack we manufacture at AceOn is unique and made precisely to the customer's specifications. We consider the chemistry, voltage, capacity, size, shape, performance, and numerous other characteristics to create the perfect solution for your application. This enables you to rely on the perfect battery to power whatever application you have, no matter how bespoke the requirements may seem.
Key Considerations:
Chemistry • Voltage • Capacity • Size & Shape • Performance Parameters
Highly customisable
Rather than using a battery pack that might power an application, custom packs enable you to create a pack specifically with the application in mind. As such, the pack is created with specific chemistries, cell arrangements, and management systems to ensure flawless application within your business. We have worked with countless businesses across numerous sectors and have the expertise to create highly customisable packs to suit various requirements.
Customisation Options:
Specific Chemistries • Cell Arrangements • Management Systems • Sector-Specific Designs
Optimised performance
As touched upon above, you can expect optimal performance from a custom pack because it has been designed specifically with your chosen application in mind. When you partner with AceOn, we deliver custom packs that are exceptionally efficient, with a long lifespan and excellent power delivery for the best possible performance.
Performance Benefits:
Exceptional Efficiency • Long Lifespan • Excellent Power Delivery • Application-Specific Optimization
Perfect for specialised applications
Most of our clients use complex custom battery packs within specialised applications, which cannot easily be powered by standard packs. For instance, many of our custom packs are used in medical devices, aerospace systems, and even electric vehicles, such is the demand for bespoke battery packs in these industries.
Industry Applications:
Medical Devices • Aerospace Systems • Electric Vehicles • Complex Specialised Applications
Ready to explore custom battery solutions for your business?
Our battery experts are standing by to discuss your specific requirements and help design the perfect custom battery pack for your application.
Technical Components
What are the main components of custom battery packs?
The battery pack manufacture process can be complex, as there are numerous key elements that must be included in a bespoke system.
That said, you will find the following components in most packs:
Battery Cells
Battery cells
The main component of any custom pack is the battery cells within it. The cells are the building block of custom packs, and are available in various chemistries, including lithium-ion, nickel metal hydride, nickel-cadmium, lithium thionyl chloride and lead-acid, depending on the requirements of your application. We can help with recommendations about the most suitable cells to use in your pack.
Available Chemistry Options:
Lithium-ion • Nickel Metal Hydride • Nickel-Cadmium • Lithium Thionyl Chloride • Lead-Acid
BMS Control
Battery management system (BMS)
For the custom pack to work as planned, the BMS monitors and manages the pack's performance when it is used with your application. This system ensures the pack is safe and efficient, and monitors things like charging, discharging, temperature, and vaultage. A high-quality BMS can prolong the lifespan of your battery pack and make it much more efficient in the long term.
Monitoring Functions:
Charging Control • Discharging Management • Temperature Monitoring • Voltage Regulation • Safety Protection
Protective Housing
Enclosure/packaging
Custom packs can be enclosed or packaged in numerous ways, again, depending on its use case. Durable materials like plastic and metal are normally used, and the packaging helps to protect the cells, while providing sufficient ventilation and insulation.
Enclosure Features:
Durable Materials • Cell Protection • Sufficient Ventilation • Thermal Insulation • Custom Sizing
Electrical Connections
Wiring
The electrical connections between the cells, BMS, and external device are facilitate by connectors and wiring. This process ensures the correct communication within the battery pack and means it integrate s seamlessly with the device it is powering.
Connection Elements:
Cell Interconnections • BMS Integration • External Device Interface • Communication Protocols • Seamless Integration
Temperature Control
Thermal management system
In some cases, a thermal management system is required to regulate the temperature of the pack and to prevent overheating. It could include things like hea sinks and thermal pads, as well as cooling fans which dissipate excessive heat generated during operation.
Thermal Solutions:
Heat Sinks • Thermal Pads • Cooling Fans • Temperature Regulation • Heat Dissipation
Need expert guidance on component selection?
Our technical team can help you choose the optimal components for your specific application requirements.
Your Journey With Us
Why choose AceOn for your custom battery packs?
At AceOn, we have been creating bespoke battery pack systems for decades for businesses in the United Kingdom and overseas. We have a specialist, in-house team at our Telford warehouse and are perfectly positioned to take on large and small orders in a short space of time.
Your complete journey from concept to delivery
1
Design
We can help you design the perfect battery pack tailored specific to the needs and requirements of a specific device. We will incoporate safety and efficiency features into the design to ensure the pack works as it should.
Tailored Solutions
Safety Features
Efficiency Focus
2
Components
We have the partnerships and supply chains in place to source all essential components to build complex battery packs, including cells, BMS, connectors, wiring, and other key components mentioned above.
Quality Parts
Reliable Supply
Full Range
3
Assembly and installation
Our in-house team then puts together your custom battery pack, assembling the cells, installing the BMS, and adding connectors and wires to make sure it works.
Expert Team
In-House Work
Quality Build
4
Testing and quality control
We rigorously test all custom battery packs that we produce before shipping them to your business. Specifically, we check for performance, safety, and capacity, conducting stress tests and temperature tests, among others, to ensure the pack is up to standard.
Rigorous Testing
Safety Checks
Quality Assured
5
Shipping
Finally, we will arrange for the safe shipping of your custom battery pack to any location in the United Kingdom. We can also arrange international shipping if required.
UK-Wide
International
Safe Delivery
Ready to start your custom battery pack journey?
Let's discuss your requirements and create the perfect power solution for your business
Get Started Today →AceOn Group
Battery Pack Division
Unit 9B Stafford Park 12, Telford, Shropshire TF3 3BJ
Phone: +44 (0)1952 293 388
Email: info@aceongroup.com
Phone: +44 (0)1952 293 388
Email: info@aceongroup.com
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