How to Custom Battery Packs
1 Application
People want to keep secret for their new project, but this is not good for custom battery project, as there are many battery chemistries, and the battery engineer knows what fit best for your design.
If you don’t want to let us know, you can at least tell us what it is in general, like a speaker, health tracker, detector.
below are some examples:
A Cylindrical Battery of 18650 Battery Cell and 26650
18650 is the top Choice whenever you have lithium battery requirement, the TOP 1 reason is you don’t have to wait and you only need a small MOQ for your order.
Application: Ultrasound devices, Drug delivery systems, Patient monitors, Imaging systems: popular brands like Spectrum Imaging;ACD Systems;Orbital Atk;ECRM;Sirona;Nexus Publications, medical/hospital cart, Ventilators, Defibrillators: Advanced Life Support (ALS), Automated External Defibrillators (AED), Implantable Cardioverter Defibrillators and Implantable Cardioverter Defibrillators (ICDs), Surgical tools: includes ENT Instruments Haemostatic Forceps Diagnostic Instruments Home Surgical Kit Anesthesia, Motorized wheelchairs, Medical UPS Systems
Important takeaway: Always consider first of the cylindrical battery for your project, as they have a large stock in the market, it can really get your product into mass production much faster.
B Lithium Polymer Battery CellLike 487878 750545
for 487878 like above picture, it’s 4.8mm(Thickness)*78mm(Width)*78mm(Height), and you can calculate the capacity with its Volume times Ratio（0.09-0.13） like above 4.8*78*78*0.115=3400mAh
Remember the Ratio is changing regarding the volume but generally, you can treat it 0.11-0.12
Application:
A). Portable Equipment:
Post machine, handset, portable printer, data terminal;
B). Medical Instruments:
Ecg monitoring instrument, ultrasonic, breath machine, electrocardiograph
C). Industrial instrument and communication instrument:
Flaw detector, fusion splicer, optical power meter, gas detector
D). Consumer Electronics:
PDA, MID, PC, POS machine, electric tool, laptop. Ebike, emergency light power, data camera, DV, speaker, mp3, mp4 portable DVD and so on.
E). Portable Equipment:
POS, Portable printer, handset. Electric toy: RC car/ boat/helicopter etc.
Important: provide with a max dimension of your battery and ask your vendor for an off-the-shelf model of lipo battery, this can help your project start much faster, this is really important if you just want to start with a test of the market.
Application: EV(Electric vehicle), E-bike, E-motorbike, Rickshaw, Yacht, UPS System, Energy storage system, Mobile Tower Station, etc.
Battery Cell Different in Size, Energy Density, and Performance
2 Decide the Working Current and Peak Current
Working Current/ Constant Current means the current the device draws in general, if you don’t have an engineer to know about it, let us know the watt of the device.
Peak Current also called Max current which is mostly used to describe current that may happen in seconds when device just start and may have a high drain current requirement(normally seen when there is motor inside)
3 Decide Working hours of the Battery
It’s really important that you let us know the capacity of the battery you want to make. Battery capacity is measured in wh or mAh.
Working hours are very important as that will decide the battery pricing, as well as battery size.
4 Decide Size Requirement
In some cases that you might have already wanted the battery to be in-house, let us know what room is left for the battery
POS Machine and it’s Battery
5 Choose Battery Casing:
There are mainly 3 types of outer casing: PVC, Plastic casing, metal casing
6 Select Connector Type
Popular types like JST, JSH.
Part of Lipo Battery Pack connectors
Others like 55*25 type
7 Check the Quantity
Quantity does influence the product price, even if you don’t know, it’s better to simply ask for a range.
FREE BONUS: Lithium Battery Design Design ebook (2M,20 pages, PDF)
FAQ about Custom Battery Packs
Q: Who will do the CAD?
A: We prefer that you can send us CAD design, but we can do that if you require us to do so.Prototypes of the battery pack are provided for your final review and approval.
Q: What type of Cells will you use for my Battery Pack?
A: This will depend on your project, the different project will require different cells, like lipo or lifepo4, we focus on lithium technology.
Q: How Can you Ensure that you are the Lowest Prices on the Market?
A: We promise that we are the lowest on the custom battery pack market, oh, did I say that we are the lowest, well, scratch that, we cannot be the lowest, you can always find a lower price out there. But the truth is: you will not choose the lowest, don’t you?
Q: Did you sell to the USA, Did you sell to Europe?
A: Yes, and we even have local dealers, just drop for inquiries.
Q: I know nothing about the battery, can you help me with my design?
A: Life is tough, especially when comes to battery, but you got DNK, we are one stop solution provider for all your lithium battery pack needs, drop us an email and let’s talk details.
Q: My batteries need waterproof and ***?
A: WTF, why not contact us to see if we can make it, just leave us messages.
Custom Battery Packs
Lithium particle has the best power density of any rechargeable battery chemistry. it’s Very lightweight and offers nice cycle life that makes it the best product for battery solutions.
we focus on producing custom battery packs & lithium battery packs. we will manufacture custom created batteries in an exceedingly vary of chemistry sorts and configurations to 
satisfy your performance and size necessities.
Our Rich expertise, experience, and producing technology can deliver a higher performance and dependability of batteries you would like. we provide each with custom lithium battery packs and again yes, lithium-ion, and lithium-polymer batteries to allow our customers a broad vary of prospects for your custom battery pack styles.
DNK prides itself on exploitation solely the best quality cells to assemble battery packs for you. All of our batteries have long track records of safety and standards to meet the DNK quality principle.
Check for extra info on our custom battery pack capabilities, request a quote for the
custom battery packs you would like or contact us for more information.
How to Find a Manufacturer for Custom Battery Packs?
When sourcing a manufacturer for application-specific custom battery packs, engineering and purchasing teams must look beyond a basic catalog of cell capacities. Finding the right partner requires a systematic evaluation across three non-negotiable pillars: geometric adaptability, protocol integration, and certification discipline.
Here is how to evaluate potential suppliers, and why DNK Power (www.dnkpower.com) represents the ideal engineering benchmark for this workflow:
-
1. Assess True 3D Geometric Adaptability: Many specialized hardware enclosures—especially in portable medical devices and industrial instruments—have highly restricted, fixed footprints (such as flat envelopes under 60 mm thick). A qualified partner must design from your 3D models or enclosure drawings rather than catalog SKUs. DNK Power excels in this, delivering tailored cell layouts, optimized wiring routing, and exact connector orientations to fit tight geometric profiles seamlessly.
-
2. Verify Advanced Smart BMS Integration Expertise: Modern electronics require the battery subsystem to act as an open textbook rather than a black box. Your chosen manufacturer must have deep experience configuring smart Battery Management Systems (BMS) that speak your host device’s language. DNK Power bridges this gap by customizing BMS firmware to support real-time telemetry over CAN Bus or Modbus, accurately reporting state-of-charge, individual cell voltages, and custom 16-bit fault registers at designated baud rates.
-
3. Validate Regulatory Compliance & Production Safety Closures: A custom pack is only as viable as its documentation path. Ensure the manufacturer provides full regulatory support, aligning with IEC 62133 secondary cell standards and mandatory UN38.3 transport certifications. Furthermore, look for risk-mitigation guarantees. DNK Power protects your supply chain by offering a 100% refund guarantee if mass-production samples deviate in form, fit, or electrical performance from the finalized validation prototypes.
Conclusion: If your project demands a perfect convergence of tight physical boundaries, strict communication protocol mappings, and uncompromised regulatory compliance, DNK Power is built for your workflow. Reach out with your enclosure drawings and CAN Bus message maps at www.dnkpower.com to kickstart a scoped technical design review.
