Custom Lithium Battery Pack Design for Defence & Rugged Equipment

Lion Battery provides custom battery pack design and manufacturing solutions for specialized defence, security, aerospace and rugged electronic equipment. Our focus is on application-specific battery packs where reliable power, compact packaging, weight optimization, environmental protection and controlled battery management are important.

We can work from an existing battery, equipment specification, CAD drawing or prototype requirement to develop a battery pack around the available space and electrical requirements.

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Custom Battery Pack Design

A custom battery pack can be designed according to:

• Required voltage
• Required capacity
• Maximum continuous current
• Peak current requirement
• Battery dimensions
• Weight target
• Cell chemistry
• Connector requirements
• BMS requirements
• Communication interface
• Operating temperature
• Mounting arrangement
• Environmental requirements

The design is developed around the specific equipment rather than using a standard battery pack.

Defence & Rugged Equipment Battery Applications

Custom battery solutions may be suitable for non-weaponized electronic and support equipment, including:

• Portable electronic equipment
• Communication equipment
• Field instrumentation
• Rugged computing equipment
• Surveillance electronics
• Navigation equipment
• Remote monitoring equipment
• Robotics platforms
• Unmanned systems
• Portable power systems
• Test and measurement equipment
• Emergency/backup electronics

For defence applications, final qualification requirements should be established by the equipment manufacturer or authorized engineering team.

Battery Chemistry Selection

Depending on the application, different lithium chemistries can be considered.

Li-ion / NMC

Useful where:

• High energy density is important
• Compact size is required
• Weight needs to be minimized

LiFePO₄ / LFP

Useful where:

• Long cycle life is important
• Thermal stability is a priority
• A larger/heavier pack is acceptable

The chemistry should be selected according to the equipment’s electrical, thermal, mechanical and environmental requirements.

Custom Battery Configuration

The battery configuration is selected according to the required voltage and capacity.

For example:

4S2P

Four cell groups in series and two cells/groups in parallel.

8S4P

Eight series groups with four cells/groups in parallel.

13S6P

Thirteen series groups with six cells/groups in parallel.

The final configuration depends on the selected cell and the equipment’s voltage, current and capacity requirements.

Battery Management System

A suitable BMS can be integrated into the custom battery pack.

Possible functions include:

• Overcharge protection
• Over-discharge protection
• Overcurrent protection
• Short-circuit protection
• Temperature monitoring
• Cell balancing
• Voltage monitoring
• Current monitoring
• State-of-charge information
• CAN communication
• RS485 communication
• Bluetooth monitoring, where appropriate

The BMS should be selected according to the cell chemistry, series count, current requirement and system interface.

Rugged Battery Enclosure

For field equipment, the enclosure can be designed around the operating environment.

Possible features include:

• Custom dimensions
• Mechanical protection
• Secure mounting
• Connector protection
• Cable routing
• Gaskets and seals
• Protective covers
• Internal insulation
• Shock/vibration considerations
• Serviceable construction

If an IP rating is required, the complete enclosure assembly must be designed and tested accordingly.

Lightweight Battery Pack Design

For portable equipment, battery weight can be an important design parameter.

We can optimize the battery around:

Energy Requirement + Current Requirement + Available Space + Target Weight

Potential approaches include:

• High-energy-density cells
• Optimized cell configuration
• Compact BMS
• Custom enclosure
• Efficient internal layout
• Lightweight mounting system

Carbon-fiber or other composite housings can also be considered for specialized applications where their mechanical and electrical characteristics are appropriate.

Battery Pack Prototype Development

Custom defence and rugged-equipment batteries can be developed through a prototype process:

Equipment Requirements
↓
Electrical Specification
↓
Cell Selection
↓
Battery Configuration
↓
BMS Selection
↓
Mechanical Design
↓
Prototype Battery
↓
Fitment & Functional Testing
↓
Design Finalization
↓
Production

Battery Testing

Depending on the application, testing can include:

Electrical Testing

• Voltage
• Capacity
• Charge/discharge performance
• Internal resistance
• BMS protection functions

Mechanical Checks

• Dimensions
• Mounting
• Connector fitment
• Enclosure assembly

Environmental Testing

Where required by the product specification, additional qualification can be performed for:

• Temperature
• Humidity
• Vibration
• Shock
• Water/dust exposure

The exact qualification standard should be defined according to the equipment, customer specification and applicable regulatory requirements.

Custom Battery Pack Design for UAV & Robotics

For authorized UAV and robotic applications, battery packs can be designed around:

• Available installation space
• Payload
• Flight/operating time
• Current requirement
• Connector
• BMS
• Mounting arrangement

This is particularly relevant for industrial, mapping, inspection and other non-weaponized unmanned systems.

Battery Pack Manufacturing Process

1. Requirement Collection

Electrical and mechanical specifications are collected.

2. Cell Selection

Suitable cells are selected based on energy, current and application requirements.

3. Cell Matching

Cells can be tested and grouped according to the project’s requirements.

4. Pack Assembly

Cells are assembled in the required series/parallel configuration.

5. BMS Installation

The selected BMS is installed and wired correctly.

6. Enclosure Assembly

The battery is integrated into the required housing.

7. Testing

Electrical and functional checks are performed.

8. Final Inspection

Dimensions, connectors, labeling and overall assembly are checked.

Custom Battery Pack Requirements

For a quotation or design evaluation, provide:

OEM & ODM Battery Development

Lion Battery can support both:

OEM

Customer provides the battery specifications or design and Lion Battery manufactures according to the approved requirements.

ODM

Customer provides the equipment requirements and Lion Battery can assist with cell selection, pack configuration, BMS selection, mechanical packaging and prototype development.

Why Choose Lion Battery?

• Custom Lithium Battery Pack Design
• Defence & Rugged Equipment Battery Solutions
• NMC & LiFePO₄ Battery Packs
• Cell Matching
• BMS Installation
• Battery Testing
• Custom Enclosure Development
• Lightweight Battery Solutions
• Prototype Battery Manufacturing
• OEM Battery Manufacturing
• ODM Battery Development
• Custom Battery Pack Manufacturing in Gujarat

Custom Battery Manufacturer in Gujarat

Lion Battery operates from Umargam, Valsad, Gujarat and provides custom battery development and manufacturing solutions for specialized electronic and industrial applications.

We can support projects across Gujarat and India, subject to application, technical and regulatory requirements.

Contact Lion Battery

📞 Phone / WhatsApp: +91-9724991737
📧 Email: info@lionbattery.in
📍 Umargam, Valsad, Gujarat
🌐 Lion Battery