Custom battery packs

A custom battery pack is developed to suit the specific electrical, mechanical, regulatory and supply requirements of an application, rather than relying on off-the-shelf formats. This allows OEMs to optimise performance, safety and integration for their end product.

Custom battery packs are commonly used in applications such as UAV, robotics, medical devices and industrial equipment, where standard battery options cannot meet performance, safety or form-factor requirements.

A custom battery manufacturer designs and produces battery packs to meet the specific requirements of an OEM product, rather than supplying off-the-shelf solutions. This typically includes defining the electrical and mechanical design, selecting appropriate cells and components, and ensuring the battery meets performance, safety and regulatory requirements. The result is a battery pack that is fully integrated with the product it powers and suitable for reliable, repeatable manufacture.

Each client is slightly different, but we manage the process end to end, with clearly defined inputs and review points – based on our tried and tested stage-gated process.

OEM teams are supported throughout, without the need to coordinate multiple suppliers or manage handovers between development and production stages.

These options represent different routes to delivering a custom battery pack, depending on application requirements and time-to-market. A detailed explanation of each route, including how they are selected and applied, is covered within our battery pack design service.

Timelines vary depending on design complexity, regulatory requirements and material lead times. Project based on our Core platforms are based on already validated designs which can be fast-tracked through to production, while TotalCustom projects require a ground-up approach where development can take 12-24 months. More information is available on our battery pack design page.

Yes. Once a custom battery pack is validated and production-ready, manufacturing is managed as part of the same programme, providing continuity from development through to ongoing supply.

Initial discussions typically focus on the application, operating environment, performance and regulatory requirements, expected volumes and target timelines.

This information allows the most appropriate route to a custom battery pack to be defined.

We develop custom battery packs either through our full custom TotalCustom programme or by adapting one of our proven Core or Core+ platforms. All projects are intended for commercial production at our UK manufacturing facility.

Alexander Battery Technologies most popular battery packs are produced using Lithium-Ion (Li-ion) or Lithium Iron Phosphate (LFP) cells, but we also produce packs using chemistries such as NCA, LTO, NiMH and more. These can be produced using cells in a variety of physical formats such as cylindrical, prismatic and pouch-based cells.

Alexander Battery Technologies is a custom battery pack manufacturer in the UK. We serve customers around the world, including Europe, USA, and Canada.