How to Order a Customised 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.

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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.

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.

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 ISO, ISO, ISO and ISO.

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.

Contact us to discuss your requirements of custom battery assembly equipment. Our experienced sales team can help you identify the options that best suit your needs.

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!

If you want a battery that lasts longer, packs more of a punch with less weight, and has a fast charge time, switching to lithium batteries is most likely the right move for you. However, not all lithium battery brands are created equal, particularly when it comes to battery safety, the company&#;s track record, and customer support. So how can you ensure you select the right brand in order to make the most out of your energy storage investment?

Here is a list of the top factors to consider when making your lithium battery selection:

1. What Is The Lithium Battery&#;s Chemical Makeup?
2. The Company Ethics
3. UN38.3 Certification
4. The Variety In Product Offerings
5. Customer Experience

What Is The Lithium Battery&#;s Chemical Makeup?

Lithium battery chemistry is significant, as it directly impacts the safety and longevity of your energy storage system. There are many different lithium battery chemistry options to be aware of, ranging from Lithium Iron Phosphate (LFP or LiFePO4) to Lithium Nickel Manganese Cobalt Oxide (NMC) to Lithium Cobalt Oxide (LCO) to Lithium Nickel Cobalt Aluminum Oxide (NCA). The most widely used lithium battery chemistries can be categorized as either cobalt-based or non-cobalt-based (e.g. LiFePO4 or LFP) lithium batteries, with the latter representing the safest, most environmentally benign, and longest-lasting lithium battery chemistries on the market.

The oxygen and the phosphorus atoms in LFP batteries are strongly linked by covalent bonding, unlike the weaker cobalt-oxide bond in cobalt-based lithium batteries like LCO, NMC, and NCA. This is advantageous because the phosphate-oxide bond offers enhanced stability. On the other hand, lithium cobalt-based batteries can release excessive heat and create fire hazards when they are overcharged or subjected to damage. Due to their superior chemistry and resulting in greater safety, LiFePO4 batteries are able to be installed on their side and in more space-restricted compartments. RELiON exclusively offers lithium batteries that utilize lithium iron phosphate chemistry for these reasons.

The Company

Although the first commercial lithium-ion battery was developed over three decades ago, the use of LFP batteries in high power applications is still relatively new. As a result, top-tier lithium battery manufacturers have had to continually innovate and build their knowledge of the technology to maintain a competitive advantage. Lithium batteries contain much more sophisticated technology than lead-acid batteries, so designing, engineering, testing, and manufacturing the highest-quality lithium batteries requires highly developed technical skills and expertise.

When considering a lithium battery brand, the experience of the company is tantamount. RELiON&#;s engineering and manufacturing teams have honed their lithium battery expertise, specialty over the past several decades and have a proven track record to stand behind with distribution networks located on nearly every continent. RELiON has cultivated a team of experts with a combined 190 years of experience and invests exclusively in people with the necessary expertise, training, and relationships to ensure customers&#; success.

The financial security and robust operations of a company are important to consider, too. With RELiON, customers don&#;t have to worry that the company won&#;t be around if they want to seek customer support down the road. RELiON&#;s recent acquisition by Brunswick, a major player in the marine industry, has taken RELiON&#;s reliability to the next level. Customers can have peace of mind that the company not only has strong financial backing but will be there to support them and their systems, should the need arise in the years to come.

UN38.3 Certification

Lithium batteries must go through a rigorous testing and certification procedure to meet UN38.3 standards and be certified for transportation. However, the responsibility of certification falls on the seller, and there are many products in the market that fail to meet the UN38.3 standard. To be approved, the battery must not rupture, leak, disassemble, or catch fire through eight rounds of testing that include altitude, thermal, vibration, shock, short circuit, impact, crush, and forced discharge testing. These tests provide an extremely important safeguard for the customers, which is why RELiON invests in the certification of all products, ensuring they meet the industry&#;s quality and safety standards.

Variety Of Product Offering

Having options for how much power and space you need is important to make sure you find the best lithium battery to fit your specific needs and application. Most lithium battery manufacturers offer limited options in terms of battery shape, size, and voltage due to the fact that it is often more cost-effective for them. However, RELiON has one of the largest LFP product offerings available - ranging from 12V to 24V to 48V batteries that power nearly every application. RELiON batteries also come in virtually any shape or size to enable you to find the perfectly sized lithium battery for a wide range of installation locations. Facilitated by the years in the field under their belt, RELiON&#;s expert engineering team has also developed the ability to customize batteries, enabling outside manufacturers to integrate them into their own products. To learn more about how to calculate your energy needs and find the optimal battery for your application and usage, visit our Lithium Battery Selector Tool.

Customer experience

Choosing a company that will work closely with you to provide expert guidance - both when you are deciding which battery to select for your specific situation as well as after you have made your purchase - is necessary when investing in lithium batteries. Being able to communicate easily with experts about this technology will ensure that you are able to get the most out of your equipment and use it hassle-free long-term.

RELiON&#;s dedicated team of customer service and technical support staff are always there for you whenever you need them. RELiON customers are able to directly engage with their experts and receive the highest-level guidance because RELiON offers users the ability to buy directly from their site, in addition to major retail stores.

RELiON has been in the industry for 20+ years, which means that as a customer, you will have a talented team of experts ready to assist you in any way. Don&#;t just take it from us though; RELiON&#;s reviews speak for themselves:

&#;Why did we switch to RELiON? Easy: their reputation. We didn&#;t have much experience with lithium batteries, but knew we&#;d be in good hands based on all of the positive feedback our friends in the RV community provided about RELiON batteries and RELiON&#;s excellent customer service.&#; - Leigh and Brian, RV campers

&#;Our experience with RELiON and their LiFePO4 batteries has been very positive from the very beginning. While installing our two RB200 batteries into our RV I had some technical questions and was connected directly with a RELiON engineer who answered them quickly and thoroughly. Now, nearly a year later, we are still 100% satisfied with the performance of our RELiON batteries.&#; - Fate Unbound, RV camper

&#;Their customer service is top-notch and their batteries have been proven time and again to be very reliable and long-lasting. I know a lot of professional anglers that have made the switch to RELiON batteries.&#; - Matt Arey, Bassmaster Elite Pro Angler

Lithium batteries can provide you with a lighter, more powerful alternative to lead-acid batteries to help you challenge your limits by spending more time on the water and off the grid. Before you decide to make the switch, it&#;s important to research which brand will help you reach your goals best by taking into consideration if a company makes LFP batteries or not, the variety they offer, and the company&#;s expertise and customer relations reputation. These are all factors that play heavily into the successful integration of lithium batteries into your energy system.

The company is the world’s best custom lithium ion battery pack assembly supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.