Lithium Battery Pack Design and Engineering for OEMs

Request a custom battery quote Configure your pack requirements

Lithium Battery Company is a battery engineering company that designs custom lithium-ion battery packs for OEM equipment, then builds them. Our engineering team turns your equipment's electrical, mechanical and environmental requirements into a pack specification, with drawings and a bill of materials you can approve, and a validation plan agreed before release. We've been designing custom lithium packs since 2014, with hundreds of thousands produced for OEM programs.

Design work leads into production programs starting at 25 units for custom packs, or 10 units for catalog packs.

Request a design review · Configure your pack requirements

What our battery pack engineering covers

  • Requirements capture. Voltage window, continuous and peak current, regenerative current, runtime, charger, available space and weight, temperature range, ingress and vibration exposure, communications, compliance and transport needs, quantities. Missing numbers are where pack programs go wrong, so we help you fill them in.
  • Chemistry and cell selection. LiFePO4 (LFP) or NMC, and cylindrical, prismatic or pouch cells, chosen against energy, current, temperature, cycle life, cost and availability. See LFP vs NMC chemistry.
  • Series/parallel architecture. Cell count in series sets the voltage window; cells in parallel set capacity and current sharing. We check the architecture against your controller's limits at full charge and at cut-off.
  • BMS specification. Protection thresholds, balancing, state-of-charge method, fault behaviour and communications (CAN or another protocol), matched to your equipment. See battery management systems.
  • Electrical protection. Fusing, current paths, conductor and busbar sizing, isolation and pre-charge where the load needs it.
  • Thermal design. Heat generation at your real duty cycle, the heat path out of the pack, and limits for charging in cold conditions.
  • Mechanical design. Cell fixing, enclosure or wrap, mounting, connector placement, vibration and shock, ingress protection target and service access.
  • Charger matching. Charge voltage, current and termination matched to the pack and BMS. See our battery charger catalog.
  • Design for production. A design that can be assembled and tested repeatably, with test points, inspection points and acceptance criteria defined up front.

What you get from the design phase

  • A pack specification with electrical, mechanical and BMS parameters
  • Drawings and a bill of materials for approval
  • A validation plan agreed before prototypes are released
  • Prototype builds for fit, function and charging tests
  • A controlled path to pilot and volume production, with change control

Design examples by application

Each application loads a pack differently, and our application guides show what we design for:

Working with an existing design

If you already have a design, we can review it, propose changes for cost, availability or manufacturability, or build it as is. See build-to-print battery packs. If you need a fast working sample, see rapid battery prototyping. For founder-led advice on cells, BMS architecture or supplier strategy without a build program, see battery industry consulting.

Timeline

Design, prototype and validation time depends on the cells, the design scope and the tests your program needs. Lead times run from weeks to months, and your quote confirms them.

What to send for a design review

Equipment and application, voltage window, continuous and peak current, runtime, charger, maximum dimensions and weight, operating and storage temperature, communications, compliance and transport requirements, first-order quantity and annual volume. Sketches, existing battery data or a current drawing all help. Request a design review.

Frequently asked questions

Do you only design battery packs, or build them too?

Both. We design custom lithium battery packs and build them through prototype, pilot and volume production under change control.

What does a battery pack design include?

A pack specification with electrical, mechanical and BMS parameters, drawings and a bill of materials for approval, a validation plan, and prototype builds for fit, function and charging tests.

Can you review or improve our existing battery design?

Yes. We can review an existing design, propose changes for cost, availability or manufacturability, or build it to print.

How long does battery pack design take?

It depends on the cells, the design scope and the validation your program needs. Lead times run from weeks to months, and your quote confirms them.

What chemistries do you design with?

LiFePO4 (LFP) and NMC lithium-ion. We recommend one from your load, runtime, weight, temperature and cost targets.

Request a custom battery quote Configure your pack requirements