4 mins Read 
24/06/2025 For an original equipment manufacturer (OEM), launching a brand-new product entails numerous design decisions. Some decisions will be quick, while others won’t, often leading to design fatigue, especially with a technically complex product. The most critical and complex choice an OEM will face is whether to opt for a custom battery pack or a pre-existing, off-the-shelf (OTS) battery pack. Although a complex decision, custom battery pack manufacturers are experts at helping OEMs make informed choices for their products. With 40 years of experience guiding our customers through their design decision journey, we want to share with you our views on when and why custom battery packs make sense.
Custom Battery Packs Can Differentiate Your Product
In a world of overcrowded segments that often produce similar products, price, performance, and appearance become the only clear differentiators. Custom battery packs are a ticket out of the race to the bottom, providing OEMs control over the appearance and power. The manufacturer can tailor their pack requirements to their application, instead of choosing “the closest fit” from a selection of pre-existing OTS solutions. The resulting pack will be unique to that product, allowing the custom manufacturer to tailor it for specific spatial or power requirements.
Smart features are a game-changer for OEMs, allowing integration with the host’s device or fleet management systems. With a custom battery pack being designed from the ground up, these innovative features can be built in from the start. These additional features can provide customers with a better experience with their product and give a USP over the manufacturer’s competition.
An OTS solution is ideal for OEMs seeking the bare minimum from their power source. OEMs seeking to differentiate themselves from their competitors and deliver top-of-the-line performance should collaborate with a custom manufacturer.
Custom Battery Packs Give Freedom Back To an OEM
A bespoke battery pack provides an OEM the chance to decide what parts go into their pack. A custom battery manufacturer meets its customers’ unique requirements to ensure their application functions effectively. These requirements can be met in the form of a special component or a power requirement. Our expert engineers design bespoke battery packs from the ground up, addressing complex requirements right from the start.
An OEM will have the freedom to design their application in any way they want, knowing their custom battery partner can create a power source that will work with their application. Take an eVTOL as an example; this concept is reliant on a tailored battery pack, as OTS solutions don’t have the power density to provide vertical flight. With a custom pack, manufacturers can focus on building a safe and robust frame, knowing that a lightweight, high-performance battery solution can be tailored to support it.
Built-in Safety and Compliance from the Start.
A custom battery design will include built-in safety features tailored to the demands of specific industries. For OEMs working in the medical, e-mobility, aerospace, or robotic sectors, their applications require critical safety features. Working with a custom manufacturer ensures your battery pack is designed to meet the specific certifications and regulatory standards required for your industry. Off-the-shelf solutions, by contrast, are often built for broad use and may lack the necessary compliance for specialised applications.
When an OTS solution makes sense
A custom battery pack isn’t right for every project. Suppose your application requires a battery with a low power output, basic safety features, no overly complicated certification, and doesn’t need a pack to meet a specific requirement. In this case, a cheaper OTS will be more due to the time and cost it will take to develop a custom pack. If you’re in the early R&D phase or only need a small production run, again, the cost and lead time associated with a custom pack won’t be the best for your project. Often, the reality with an OTS solution is that you’re accepting what the pack can do for you, rather than building a battery designed to meet your product’s specific needs.
Where does ABT fit in?
Alexander Battery Technologies has been guiding OEMs through their custom battery pack journey for over 40 years. We provide expert guidance throughout the project to make their journey as smooth as possible. ABT can deliver high-quality, high-power custom battery packs at high volumes to OEMs looking to scale up their production needs. The support we provide does not end when we finish delivering your pack. We offer full after-sales support and look forward to seeing how we can help our customers in the future.
Ready to power your product with a custom battery solution built around your needs? Partner with ABT and let’s bring your vision to life.
