Customized Battery Pack Development

At CM Batteries, our team has realized the development of a customized battery pack is a complex and professional process. Over the years, we have boosted every stage of the process from concept to mass production. The optimal journey of custom battery pack development will save your cost and time and make your sales successful.

Complete Concept Battery Pack Development
Battery Pack Specialty Process Design
Established Specification Battery Pack Design
Battery Packs Design/Build for Certification

Let’s take a closer look at the guidance of the four processes.

Complete Concept Battery Pack Development

In the early stage, some customers are confused about how to get custom batteries. Our engineering and consultant team works closely with you to clarify your needs and create a scope of questionnaires for development. The custom battery packs will take more time to develop. The first step is to determine the basic parameters and your specific needs. Once you confirm the concept battery pack development, the estimation will be released with a quotation, technical proposal, and development time.
This stage will take 2-10 working days to confirm the development concept and realise the solution estimation.

Examples of applications we have developed in this way include:

Marine Equipment Battery

A marine equipment company from the US wants to develop a new waterproof lithium battery pack. The tailored battery pack is required with waterproof, corrosion-resistant, and Bluetooth. First, we conduct surveys of our customers from the application environment, sample testing, technical request, and their target market and customers.CMB has offered a unique waterproof enclosure design with a mature waterproof sealing silicone process. The battery pack request is a nominal voltage is 25.6V and the nominal capacity is 105Ah with waterproof IP68,self-heating, and Bluetooth. The battery pack solution is made of 3.2V 32700 6Ah LiFePO4 cells with a high discharge rate and integrated with heating pads. The BMS is integrated with Bluetooth. From initial concept to design approval, the entire process took approximately 10 days. Offering free design fees reduced the development costs. But when some components belong to subcontractors and have to be customized, the development fees will be charged once you start the sample production stage.

Agricultural Robots Battery

A team of engineers from a major agricultural equipment manufacturer wanted to design a new agricultural robot battery. It also requires all certifications, with a particular UL certification. Additionally, they wanted a BMS communication protocol with sleep mode and cell balance. The concept stage took 25 days to clarify the needs and go to the next step sample order confirmation.

The timeline of the agricultural robot battery development from concept to mass production.

Stage	Delivery Time
Concept	2~20 working days according to the project complexity.
Sample Order	10~35 working days according to the project’s complexity.
Samples Shipping time	4-7 working days.
Certificates Approval	25~45 working days, UL certification verify takes the longest time.
Enclosure Tooling	35~40 working days.
BMS Sample	5~35 working days, smart BMS function should verify and learn for a while.
Mass Production	25-30 working days

Battery Pack Specialty Process Design

When the device is equipped with the unique battery pack specification, you should work with the battery pack manufacturers that specialize in battery pack projects. Investing in specific equipment and battery technology will complete these processes cost-effectively. Some examples of specialized processes that may impact timelines.

Potting The Waterproof Battery Packs with Different Materials

IP rating has the different potting process requests. Clarify your equipment operation environment. The main components are included:

Waterproof ring
Plastic enclosure
Waterproof epoxy potting

The potting craft and materials have an impact on the waterproof IP rating. One professional engineering team will help your devices successfully gain the market with waterproof battery packs.

Precise Battery Pack Assembly

When the battery pack has a compact dimension, the precise assembly will solve this issue. The core factors are included:

Skilled workers
Degree of automation with advanced equipments
One professional engineering team
Strict quality control management system
Jig and fixture as a production tool

The precise battery pack assembly assures reliability. At CM Batteries, we are devoted to manufacturing li-ion battery packs with precise assembly processes for various of industrial applications.

Self-Heating Solutions

Some equipment should be operated in extremely low-temperature environments. When the li-ion battery packs work in that environment, the performance significantly drops. With over 10 years of experience in battery pack design and manufacturing, we adopt the thin silicone rubber heaters and ultra-thin Kapton heaters to make the battery packs self-heating., we can design precise solutions for each application to enhance performance in cold environments.

Providing Specialized Connectors or Harnesses Service

Specialized Connectors

The customers are assembled with custom connector solutions for their battery packs to support discharge and charge current, even matching the connector from their devices.

Harnesses

The complex cables are used for charging, discharging, and monitoring safety. By designing and installing various of harnesses, we can ensure the reliability and well fit to their devices.

Immersion Cooling Technology for Thermal Temperature

CM Batteries are focusing on to solve the thermal temperature issues to boost the reliablity of the battery pack.When the battery pack discharge with high current in the sealing space,the temperature will increasing which bring fire or damage risk.
How to grap the discharge current and peak discharge current is very important for the reliablity.The key parameters should be provided and included:

Capacitive load current from your device system
The work time for peak discharge current

Once our engineering team gets both of the parameters, we’ll design the battery pack with immersion cooling technology and pre-charge function in the BMS.

Established Specification Battery Pack Design

Your detailed specification, by filling out our comprehensive questionnaires, supports you in getting accurate quotations and efficient development of custom battery packs. It significantly reduces development timelines and sets a clear path to production.

Hardware Development
Software Development
Mechanical Design
Environmental Requirements
Certification Management
Quality Management
Testing and Programming

Battery Pack Design/Build for Certification

At this stage, customers are clear on the concept of their electrical and mechanical requirements, including preliminary designs or prior battery development experience. These stages accelerate the development process and reduce costs.

Slight Customization Ranges

Integration with standard Battery Management System (BMS) components
Design completion and certification for IEC, UL, or UN 38.3 standards
Upgrading existing battery pack solutions free

The verified certifications are subcontracted to the authoritative certification agencies .

What You Do

1. Answering questionnaire with detailed parameters (such as voltage, capacity, application, connector, discharge current and peak discharge current, dimension, etc.)
2. Preferred cell chemistry (LiFePO4 or NCM)
3. Enclosure specifications (If you need to design an enclosure)

2D exterior drawings (minimum)
3D drawings (preferred)
Includes enclosure materials, draft angle, texture, and connector position)

Our Value-Added Services

Certification Management:

Submission process handling
Sample preparation and submission
Annual renewal management
Adaptation to evolving regulatory requirements

Compliance Assurance:

1. Labeling, packaging, and shipping method verification
2. DOT regulation adherence
3. Management of special requirements

This advanced-stage approach leverages the customer’s preparatory work, allowing our team to focus on refinement, certification, and production optimization. Our expertise ensures a smooth progression from concept to certified, market-ready battery packs, while maintaining compliance with all relevant regulations and standards.