Battery Pack Design Service

Custom Battery Pack Design Service | Lithium-Ion & LiFePO₄ Battery Engineering

Lion Battery provides professional Battery Pack Design Services for businesses, startups, OEMs, product developers, EV manufacturers, robotics companies, drone manufacturers, and industrial equipment manufacturers.

We design custom NMC, Li-ion and LiFePO₄ (LFP) battery packs based on required voltage, capacity, current, dimensions, operating conditions, BMS, charging requirements, and application.

What Is Battery Pack Design?

Battery pack design is the process of converting an application’s electrical and mechanical requirements into a suitable battery configuration.

The design process can include:

Application Requirements → Cell Selection → S/P Configuration → BMS Selection → Electrical Design → Mechanical Design → Prototype → Testing → Production

Our Battery Pack Design Services

Custom Battery Pack Design

We design battery packs according to your specific requirements rather than using a one-size-fits-all configuration.

Design parameters may include:

• Nominal Voltage
• Maximum Voltage
• Minimum Voltage
• Capacity
• Energy
• Continuous Current
• Peak Current
• Charging Current
• Battery Dimensions
• Maximum Weight
• Cell Chemistry
• Cell Format
• BMS
• Charger
• Connectors
• Communication
• Operating Temperature

Battery Series & Parallel Configuration

One of the most important parts of battery pack design is selecting the correct series (S) and parallel (P) configuration.

Series Connection

Connecting cells in series increases the battery voltage.

Parallel Connection

Connecting cells in parallel increases the available capacity and current capability, subject to cell specifications.

For example, a 13S7P configuration contains:

13 cells/groups in series × 7 cells in parallel

The actual battery voltage and capacity depend on the selected cell chemistry and cell specifications.

Battery Cell Selection

We help select suitable cells based on the application.

NMC / Li-ion Cells

Commonly used where high energy density and power-to-weight characteristics are important.

Applications include:

• EVs
• E-Bikes
• Drones
• Robotics
• Portable Equipment

LiFePO₄ Cells

Commonly used for stationary energy storage and applications where cycle performance and safety characteristics are important.

Applications include:

• Solar
• ESS
• UPS
• Inverter Batteries
• EVs
• Industrial Systems

18650 & 21700 Battery Pack Design

We provide design support for cylindrical cell formats including:

• 18650
• 21700

Design considerations include:

• Cell capacity
• Discharge rating
• Internal resistance
• Cell dimensions
• Series configuration
• Parallel configuration
• Cell holders
• Nickel interconnections
• BMS requirements

Cells should be selected based on the complete electrical and mechanical requirements, not only their physical size.

BMS Selection & Integration

The BMS is an important part of the battery pack design.

We help determine suitable BMS requirements based on:

• Battery Chemistry
• Series Count
• Continuous Current
• Peak Current
• Charging Current
• Cell Balancing
• Temperature Sensors
• CAN
• RS485
• UART
• Bluetooth

The BMS should be matched to the cells, pack configuration, charger, inverter/controller, and application.

Battery Enclosure & Mechanical Design

A battery pack must fit securely within the available installation space.

Mechanical design considerations include:

• Battery Dimensions
• Cell Arrangement
• Enclosure Size
• Mounting Points
• Connector Position
• Cable Routing
• Insulation
• Service Access
• Environmental Protection
• Weight Distribution

For mobile applications, mechanical strength and vibration resistance are also important design considerations.

Thermal Design Considerations

Battery pack design should account for heat generated during charging and discharging.

Depending on the application, design considerations may include:

• Cell Spacing
• Airflow
• Heat Dissipation
• Temperature Sensors
• Operating Temperature
• Charging Current
• Discharge Current
• Enclosure Design

High-power battery systems may require additional thermal-management engineering.

Battery Pack Design for Different Applications

EV Battery Pack Design

Custom battery design for:

• Electric Cars
• Electric Scooters
• Electric Motorcycles
• Electric Three-Wheelers
• Golf Carts

E-Bike Battery Design

Custom packs based on:

• 36V
• 48V
• 52V
• Other application-specific configurations

Drone Battery Design

Design considerations include:

• Low Weight
• High Discharge Capability
• Required Flight Time
• Pack Dimensions
• Connector
• C Rating

Solar & ESS Battery Design

Custom LiFePO₄ packs for:

• Home Energy Storage
• Solar Systems
• ESS
• Off-Grid Systems
• UPS
• Inverter Applications

Robotics Battery Design

Battery packs can be designed for:

• UGV
• AGV
• AMR
• Warehouse Robots
• Industrial Robotics

Battery Pack Design Process

Step 1 – Application Requirements

We collect information about the equipment and its electrical requirements.

Step 2 – Electrical Calculations

Voltage, capacity, current and energy requirements are evaluated.

Step 3 – Cell Selection

Suitable cell chemistry, format and specifications are selected.

Step 4 – S/P Configuration

The required series and parallel arrangement is established.

Step 5 – BMS Selection

BMS specifications are determined according to the battery design.

Step 6 – Mechanical Design

Battery dimensions, mounting and enclosure requirements are considered.

Step 7 – Prototype

A prototype battery pack can be developed where required.

Step 8 – Testing

The battery can undergo appropriate electrical and functional testing.

Step 9 – Production

After design validation, the battery can proceed to custom manufacturing.

Battery Pack Testing

A designed battery pack may be evaluated through:

• Voltage Testing
• Capacity Testing
• Internal Resistance Testing
• Charge Testing
• Discharge Testing
• Cell Balance Testing
• BMS Testing
• Temperature Monitoring
• Connector & Wiring Inspection

Testing requirements depend on the battery application and design.

OEM & ODM Battery Pack Design

Lion Battery provides battery design support for companies developing their own products.

Suitable for:

• OEM Manufacturers
• Product Startups
• EV Companies
• Solar Companies
• Robotics Companies
• Drone Manufacturers
• Industrial Equipment Manufacturers
• Medical Equipment Manufacturers

We can support projects from initial battery specification through prototype and custom production.

Information Required for a Battery Design

To start a custom battery pack design, provide:

1. Required Voltage
2. Required Capacity / Ah
3. Power or Current Requirement
4. Operating Time
5. Maximum Battery Dimensions
6. Maximum Weight
7. Application
8. Battery Chemistry Preference
9. Charger Specification
10. BMS / Communication Requirement
11. Connector Requirement
12. Expected Quantity

If some specifications are unknown, the application and load information can be used to determine suitable requirements.

Why Choose Lion Battery?

• Custom Lithium Battery Pack Design
• NMC & LiFePO₄ Expertise
• 18650 & 21700 Pack Design
• BMS Selection & Integration
• Cell Matching
• Battery Testing
• Prototype Development
• Battery Pack Assembly
• OEM & ODM Manufacturing
• EV Battery Solutions
• ESS Battery Solutions
• Drone & Robotics Battery Solutions

Frequently Asked Questions

What is a battery pack design service?

It is a technical service for designing a battery pack according to voltage, capacity, current, dimensions, BMS, charging, mechanical and application requirements.

Can you design a custom lithium battery?

Yes. Lion Battery provides custom NMC and LiFePO₄ battery pack design services.

Can you design 18650 and 21700 battery packs?

Yes. Battery packs using 18650 and 21700 cells can be designed according to the required voltage, capacity, current and physical dimensions.

Can you design an EV battery pack?

Yes. Custom battery designs can be developed for electric cars, scooters, motorcycles, three-wheelers, golf carts and other EV applications.

Can you manufacture the battery after designing it?

Yes. Battery pack design can be combined with prototype development, testing, assembly and custom battery manufacturing.

Contact Lion Battery

Lion Battery

📞 Phone / WhatsApp: +91-9724991737
📧 Email: info@lionbattery.in
🌐 Website: lionbattery.in