Custom Battery Pack Design
From concept to production, our expert engineers design bespoke battery solutions tailored to your exact power requirements, budget, and application specifications.
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Battery Solutions Engineered for Your Application
AceOn has many years experience in battery pack design according to your power requirements, your budget and your time-frame. It is important to design the correct battery solution to maximise the potential of your application. How do you design a battery pack that that meets your budget, power and size requirements? Speak to our battery specialists who have designed a variety of different battery solutions in the UK.
We have a team of mechanical and electronics engineers that can offer you a customised battery pack design with the most suitable battery chemistry and configuration. No project is too small, too large or too complicated.
We have provided battery pack solutions for a variety of different industries such as defence, medical, oil & gas and automotive.
Your custom designed battery pack will be developed and built in the UK and our battery design and manufacturing team have the capability of working with you throughout the whole battery design and manufacturing process. We can build prototypes as well small to large scale battery pack production.
Battery Pack Design Process
From initial consultation to production, we guide you through every step of the custom battery design journey
Initial Consultation
Discuss your application requirements, power needs, budget constraints and project timeline with our specialists.
Technical Design
Our engineers develop detailed specifications, selecting optimal chemistry, configuration and safety systems.
Prototype Development
Build and test prototype units to validate design performance against your exact requirements.
Testing & Certification
Rigorous testing ensures compliance with industry standards and regulatory requirements.
Scale Production
From small batches to large-scale manufacturing, we deliver consistent quality at any volume.
What We Deliver
Custom Configurations
Tailored voltage, capacity and form factor designs to fit your exact application requirements and physical constraints.
Chemistry Selection
Expert guidance on lithium-ion, LiFePO4, NiMH, NiCd, and other chemistries to optimise performance for your use case.
BMS Integration
Advanced Battery Management Systems with cell balancing, protection circuits, and smart monitoring capabilities.
Safety Engineering
Built-in protection against overcharge, over-discharge, short circuit, and thermal events for reliable operation.
Communication Protocols
Integration of SMBus, I2C, CAN bus, RS485 and other protocols for seamless system communication.
Enclosure Design
Custom housings with appropriate IP ratings, thermal management, and connector solutions for your environment.
Sectors We Serve
The AceOn Advantage
30+ Years Industry Experience
Decades of expertise in battery technology, design innovation, and manufacturing excellence across multiple sectors.
100% UK Design & Manufacturing
All design work and production takes place in our UK facilities, ensuring quality control and rapid communication.
Scalable Production Capability
From single prototypes to high-volume production runs, we have the capacity to grow with your requirements.
End-to-End Project Support
Our team works alongside you from initial concept through to production and ongoing technical support.
Key Design Considerations
Application power requirements and discharge profiles
Operating environment and temperature range
Physical size and weight constraints
Cycle life and longevity requirements
Certification and regulatory compliance needs
Budget parameters and volume projections
Charging requirements and protocols
Safety and protection requirements
Battery Pack Design FAQ
What information do you need to start a custom battery design project?
To begin your custom battery pack design, we'll need details about your application's power requirements (voltage, capacity, discharge rates), physical constraints (size, weight, form factor), operating environment (temperature range, humidity, vibration), required certifications, and your projected volumes and budget. Our team will guide you through the specification process during the initial consultation.
How long does the custom battery design process take?
Typical design timelines range from 4-12 weeks depending on complexity. Simple configurations may reach prototype stage in 4-6 weeks, while more complex designs requiring custom BMS development or specific certifications may take longer. We'll provide a detailed timeline during project scoping and keep you updated throughout the process.
What battery chemistries do you work with?
We design with all major battery chemistries including Lithium-ion (Li-ion), Lithium Iron Phosphate (LiFePO4), Nickel Metal Hydride (NiMH), Nickel Cadmium (NiCd), and various primary lithium cells. Our engineers will recommend the optimal chemistry based on your application requirements, balancing factors like energy density, cycle life, safety, and cost.
What is the minimum order quantity for custom battery packs?
We're flexible on order quantities - from single prototypes for testing through to high-volume production runs. No project is too small or too large. We understand that many projects start with small quantities for evaluation before scaling up, and we're happy to support this approach.
Can you help with certification and compliance?
Yes, we design battery packs to meet relevant standards including UN38.3 for transport, IEC62133 for safety, and industry-specific requirements for medical, defence, and other regulated sectors. We can guide you through the certification process and ensure your battery pack meets all necessary compliance requirements.
Ready to Start Your Battery Pack Project?
Speak with our engineering team today to discuss your requirements and discover how AceOn can deliver the perfect battery solution for your application.