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Battery pack design services

Flexible battery design for OEMs, with platform-based routes to production in as little as 6 months.

Choose from our proven platforms or fully custom battery development, with every project designed for series manufacture at our UK facility.

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Fast-to-market platform-based design options

Fully custom battery packs engineered to fit your product

Controlled, transparent, and stage-gated process

Design-to-production in one ISO9001 certified UK facility

Tier-1 cells and components for dependable performance

Custom battery pack design that leads to reliable, production-ready performance.

Our battery pack design approach gives OEMs a clearer, faster route to a production-ready solution. With structured stages and support from our engineering and manufacturing teams, projects move smoothly from early concept into volume production.

Platform-based, fully custom and build-to-print options are available, depending on your technical and commercial requirements.

Compare your battery design options

Your battery programme may require a fast-tracked, platform-based approach or a fully custom design. The right route depends on your electrical, mechanical, compliance and commercial requirements.

If your requirements are still taking shape, we work with you to define specifications and establish a clear path to production before moving into detailed design.

For projects with an existing battery design, we also support build-to-print manufacture.

We offer design services as part of a complete design-to-manufacture project, with a commitment to volume production. We do not provide battery design as a standalone service.

Core

Our proven electronics and firmware, with custom housing.

Built on our proven hardware and firmware libraries with custom housing. A fast, predictable route into production for straightforward requirements.

Core+

As Core, with advanced features and customisation.

Enhanced flexibility for non-standard functions, including new component development and extended firmware capability, as well as industry-specific regulatory requirements.

TotalCustom

A fully custom battery designed from the ground up.

A fully bespoke hardware and firmware design to meet your technical specification and/or enhanced regulatory requirements.

Core Core+ TotalCustom
Timescale Appx. 6–9 months to production Appx. 9–12 months to production Appx. 12–24 months to production
Cost £ ££ £££
Design Scope Our existing platform with custom housing. Our existing platform with custom housing and added features. Designed ‘from scratch’ to your requirements.
Regulatory & Conformance UN 38.3 UN 38.3
Standard industry/battery standards (non-complex)
UN 38.3
Complex industry/battery specific standards (e.g. automotive/military)
Technical Features – Our standard library BMS
– Our standard library firmware
– Basic modifications (e.g. custom IC config, LED behaviour, protection thresholds etc.)
As per Core, plus:
– Non-standard hardware or firmware development
– Advanced features (e.g. accelerometer, CAN/custom comms protocol, Bluetooth etc.)
– Complete flexibility on BMS, firmware and hardware
– Multiple advanced or custom features
Manufacturing Service All of our projects progress to volume production at our UK battery pack manufacturing facility.

We offer battery design for drones, robotics, power tools, medical devices, and many other applications. Talk to us to discuss your specific battery pack design requirements.

Is this the right battery design route for your project?

Our design and manufacturing services are suited to OEMs who:

  • Need a battery pack developed for commercial production volumes.
  • Require semi-custom or fully custom battery pack design.
  • Want support across design, testing, compliance and manufacturing.
  • Are developing products for sectors such as drones, robotics, medical devices, health and safety products, and power tools among others.
  • Want a battery partner focused on high performance and dependable quality, using stringent processes and high-quality cells, components and materials.
  • Require confidence that the battery is designed for reliability, repeatability and scalable manufacturing.

Start your battery programme

Why OEMs choose us

Proven capability
40+ years in battery manufacturing.
15 million battery products supplied globally.

Quality and compliance
ISO 9001 and ISO 45001 certified.
Battery Passport ready with traceability via IFS Cloud.

Integrated services
Full in-house design, testing and assembly.
Trusted by OEMs across Europe, US and Canada.

The Industries We Serve

Robotics AGV

Robotics / AGV

Custom battery packs for autonomous vehicle solutions, robotics, AGV’s and AMR’s in industries such as agriculture and industrial warehousing.

Specialised & Industrial Power Tools

Specialised & Industrial Power Tools

Specially developed lightweight battery solutions to drive powerful motors in industrial tools such as impact drivers, angle grinders, industrial cordless drills and more.

Drone

Aviation & UAV

Battery packs designed and manufactured using high-quality lithium-ion and lithium ferrous phosphate battery cells for the aviation and UAV industry.

Delivery drone

Commercial Drones & UAVs

UAV and Commercial Drone Battery Manufacturer

eVTOL battery pack in motion

eVTOL

eVTOL Custom Battery Pack Manufacturer

medical devices

Medical

Custom battery packs developed for medical devices, instruments and equipment which are battery-powered.

medical devices

Custom Battery Packs for Hospital Devices

Custom Battery Packs for Hospital Equipment

Health & Personal Safety

Health & Personal Safety

We design and manufacture battery packs for safety products including emergency lighting, hearing protection equipment and powered air personal respirators (PAPR).

Yellow underwater agv

Marine

Custom battery packs for marine leisure solutions; jetskis, seabobs and electric boats.

Test & Measurement

Test & Measurement

Battery packs and charging solutions developed for acoustic and thermal imaging equipment, calibration tools, network testers, electrical tools, HVAC meters and more.

Emobility

E-Mobility

Electrification solutions for e-mobility applications from micro-mobility to heavy equipment such as e-motorbikes, drones & UAV, e-boats, EVs and e-scooters.

electric motorbike

Electric Motorbike

Electrification solutions for electric motorbikes.

E-bike

Electrification solutions for electric bikes.

Home & Garden

Home & Garden

Bespoke battery packs and chargers for power tools, vacuum cleaners, lawnmowers, household appliances and more home and garden products.

Telecommunications

Telecommunications

From telecoms to GPS and tracking hardware, made-to-specification battery packs for navigation devices, private mobile radio (PMR), asset tracking and monitoring.

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FAQs

  • How do I choose the right battery design option? x button

  • Can you support new battery product ideas that are still in development? x button

  • What does ABT’s OEM battery design and manufacturing service include? x button

  • How long does it take to design a custom battery pack? x button

  • How much does a custom battery design cost? x button

  • Will a battery pack manufacturer help if I already have a battery design that needs improving? x button

  • How do I make sure my custom battery design meets safety standards? x button

  • Does Alexander Battery Technologies provide a one-off battery design service? x button

  • What cell chemistries do Alexander Battery Technologies design and build into battery packs? x button

  • Do you still offer battery pack design and assembly services? x button

Get in touch to discuss your battery design-to-manufacture project

Complete the form below to provide as much information as possible about the battery application, specifications, volumes, and timelines. A member of our team will be in touch to discuss your project in more detail.

Please note that we do not provide standalone battery design services or prototype-only or one-off battery designs; all projects lead to manufacturing at commercial volumes.

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Challenges in choosing the right battery design route.

Many OEMs begin with an off-the-shelf battery in mind, only to find it won’t meet performance, regulatory or space requirements. Others know they need a custom battery design, but are not sure where to start.

We offer platform-based, custom and build-to-print routes, making it easier to choose the level of design involvement that fits your project. Whether you’re adapting an existing idea or starting from scratch, we’ll guide you to the approach best suited to your requirements and timelines.

Designing for scalable manufacturing from day one.

Our battery design services are structured around manufacturability, ensuring concepts progress into controlled, repeatable production at our UK facility. Each project is developed with commercial volumes in mind, not prototypes.

With design, testing, regulatory management, sourcing and production all under one roof, OEMs gain a smooth route from early concept to a production-ready battery pack.

Do you have a project that needs a custom battery pack?