Custom Battery Guide: Everything You Need to Know - Kamada Power

In today’s technology-driven world, custom battery solutions are becoming increasingly crucial. Whether for solar applications, electric vehicles, or specific electronic devices, custom batteries offer tailored solutions to meet specific requirements. This article explores different types of custom batteries, their applications, and key factors to consider during design and manufacturing, helping you make informed decisions.

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 custom powerwall battery

1. Battery Types

1.1 Custom Rechargeable Batteries

Custom rechargeable batteries are essential in modern electronics. Opting for custom rechargeable batteries ensures minimal capacity loss during frequent charge cycles. These batteries find wide applications in consumer electronics, medical devices, and portable tools. Our custom rechargeable batteries solutions offer the following advantages:

• Durability: High performance maintained across multiple charge-discharge cycles.
• Capacity: Higher capacity for extended device runtime.
• Fast Charging: Rapid charging capabilities to reduce downtime.

1.2 Custom Batteries

Custom batteries cater to unique requirements such as specific sizes, shapes, voltage or capacity needs, high discharge rates, or enhanced safety mechanisms. Our custom battery services include:

• Fit-for-Purpose: Batteries precisely match physical and electrical requirements of the device.
• Tailored Services: Comprehensive customization from design to manufacturing.
• Reliability: Stable performance even under extreme conditions.

1.3 Custom Lithium Battery

Lithium batteries are renowned for their high energy density and long cycle life, suitable for applications ranging from portable electronics to large-scale energy storage systems. Our custom lithium battery solutions offer:

• Energy Density: Higher energy density ensures longer device operation and lighter battery weight.
• Cycle Life: Batteries withstand multiple charge-discharge cycles without performance degradation.
• Safety: Multiple safety protections including explosion and fire resistance.

1.4 Custom Lithium Ion Battery Packs

Lithium-ion batteries feature high energy density, low self-discharge, and long service life. Our custom lithium ion battery packs provide:

• Efficiency: High energy density and low self-discharge maintain operational readiness after prolonged non-use.
• Thermal Management: Effective thermal management prevents overheating for safe operation.
• Environmental Friendliness: Low self-discharge and long life reduce battery replacement frequency, meeting environmental demands.

1.5 Custom LiFePO4 Battery

LiFePO4 batteries are known for their safety, long cycle life, and thermal stability. Our custom LiFePO4 battery solutions offer:

• Safety Performance: Particularly suitable for high safety requirement applications like medical devices and electric vehicles.
• Longevity: Reduced battery replacement frequency lowers overall costs.
• Thermal Stability: Stable operation even in high-temperature environments.

1.6 Custom LiPo Battery

Lithium polymer (LiPo) batteries are favored for their lightweight and flexible design. Our custom LiPo battery solutions provide:

• Portability: Critical for weight-sensitive applications like drones and portable devices.
• Flexibility: Batteries designed in various shapes and sizes to fit different devices.
• High Discharge Rates: Suitable for devices needing high instantaneous power output.

2. Application Scenarios

2.1 Custom Solar Battery Packs

Solar systems require efficient and reliable energy storage to manage solar intermittency. Our custom solar battery packs offer:

• High Capacity: Store sufficient energy to power devices even during low sunlight periods.
• Long Cycle Life: Frequent charge-discharge cycles without significant performance reduction.
• Environmental Resilience: Operate reliably in extreme weather conditions.

2.2 Custom Low Speed Vehicle Battery Solutions: AGV, Forklift, and Golf Cart Batteries

Custom low speed vehicle battery solutions play a crucial role in applications such as Automated Guided Vehicles (AGVs), forklifts, and golf carts, ensuring reliable power sources for sustained performance.

Custom AGV (Automated Guided Vehicle) Batteries

AGVs are integral to automated warehouses and factories, demanding batteries with the following characteristics:

• High Energy Density and Longevity: AGVs require high energy density batteries to store sufficient power for extended operations, while longevity ensures durability through multiple charge-discharge cycles.
• Fast Charging and Stability: Rapid charging reduces downtime, while stable performance ensures consistent power output in diverse operational environments.

Custom Forklift Batteries

Forklifts are essential in warehousing and logistics, necessitating batteries that offer:

• Durability and Longevity: Able to withstand rigorous use and frequent charging cycles.
• Fast Charging Capability: Minimizing downtime and maximizing operational efficiency.
• Stability: Providing consistent power under varying loads and environmental conditions.

Custom Golf Cart Batteries

Golf carts rely on batteries that deliver:

• Reliable Performance: Ensuring sustained power for prolonged periods on the golf course or other recreational settings.
• Long Cycle Life: Withstanding frequent charge-discharge cycles without significant degradation.
• Safety Features: Including measures to prevent overheating and ensure safe operation.

These custom vehicle battery solutions are tailored to meet specific requirements, enhancing efficiency, longevity, and safety across various applications.

2.3 Battery Storage Custom Solutions

Battery storage solutions are critical for applications ranging from residential energy storage to large-scale industrial backup systems. Our custom battery storage solutions offer:

• High Capacity: Store sufficient energy to meet peak power demands.
• High Efficiency: High energy density and conversion efficiency reduce energy losses.
• Safety: Include multiple protective measures to prevent overcharging, over-discharging, and short circuits.

2.4 Custom Batteries for Specific Use Cases

Some applications require tailored battery solutions beyond standard offerings. We provide the following custom batteries:

2.4.1 Custom Batteries for Carts

Carts and similar equipment require robust, reliable batteries. Our custom batteries offer:

• High Load Capacity: Stable power supply under high load conditions.
• Durability: Withstand prolonged use and frequent charging.
• Safety: Ensure safe operation in diverse operational environments.

2.4.2 Custom Batteries for Electronic Devices

Electronic devices require compact, efficient, and reliable batteries. Our custom battery solutions include:

• High Energy Density: Ensure longer device operation despite compact design.
• Fast Charging: Meet the demands of frequent use.
• Safety: Include features like leak-proofing and explosion resistance.

3. Custom Battery Requirements

3.1 High Performance

High performance is crucial in custom battery design. Our battery designs offer:

• Energy Output: Efficient energy output for extended device operation.
• Low Internal Resistance: Reduce energy loss and heat generation, enhancing overall efficiency.
• Thermal Management: Effective thermal management to prevent overheating and prolong battery life.

3.2 Longevity

Longevity reduces total ownership costs and ensures application reliability. Our battery designs ensure:

• High Cycle Life: Batteries maintain high performance over multiple charge-discharge cycles.
• Stability: Stable battery performance during long-term use.
• Reduced Replacement Frequency: Lower costs associated with replacements and maintenance.

3.3 Lightweight

Lightweight batteries are crucial for weight-sensitive applications. Our lightweight battery designs offer:

• Lightweight Materials: Use of lightweight materials to reduce overall battery weight.
• Optimized Design: Optimize battery weight while ensuring performance.
• Portability: Design for ease of portability and use.

3.4 Safety

Safety is paramount in custom battery design. Our safety designs include:

• Overcharge Protection: Prevent risks associated with overcharging.
• Short Circuit Protection: Prevent safety issues arising from short circuits.
• Thermal Management System: Prevent overheating for safe operation.

3.5 Custom Size and Shape

Custom batteries need to fit specific sizes and shapes. We offer:

• Precise Dimensions: Ensure batteries fit devices perfectly.
• Flexible Designs: Design batteries in various shapes to meet device requirements.
• Space Optimization: Maximize use of internal device space for enhanced performance.

3.6 High Conductivity

High conductivity is critical for efficient energy transfer and performance. Our high conductivity batteries provide:

• Low Internal Resistance: Ensure efficient energy transfer and reduce energy loss.
• High Conductive Materials: Use of high conductive materials to enhance overall efficiency.
• Stable Performance: Maintain high conductivity even under high load conditions.

3.7 Durability

Durability is a key consideration, especially for harsh environments or heavy use applications. Our durability battery designs offer:

• High Durability Materials: Use of durable materials to extend battery life.
• Environmental Adaptability: Adapt to different environmental conditions while maintaining stable performance.
• Robust Design: Design batteries to withstand physical stress and temperature variations.

4. Custom Battery Manufacturing and Design

4.1 Professional and Experienced Manufacturer

Choosing a professional and experienced custom battery manufacturer is crucial. We excel in the following areas:

• Expertise: Kamada Power has extensive experience in battery design and manufacturing.
• Advanced Technology: Use of cutting-edge technology ensures high-quality products.
• Reliability: Kamada Power maintains a strong reputation for reliable product quality, adhering strictly to ISO quality management system for quality control.

4.2 Reliable Design and Manufacturing Processes

Reliable design and manufacturing processes ensure product quality and performance. Our custom battery design and manufacturing processes include:

• Precise Design: Each battery is meticulously designed for optimal performance.
• High-Quality Materials: Use of high-quality materials to enhance overall battery performance.
• Strict Testing: Rigorous testing ensures batteries meet specifications and requirements.

4.3 Custom Designs to Meet Specific Requirements

Meeting specific requirements with custom designs is crucial. Our specific requirement custom battery design offer:

• Personalized Solutions: Tailored designs based on your specific needs.
• Flexible Production: Kamada Power can adjust production processes flexibly to meet diverse requirements.
• Performance Optimization: Through custom design, Kamada Power maximizes battery performance.

Conclusion

Custom battery solutions play a vital role in modern technology applications. Kamada Power guides you through different battery types, application scenarios, and key considerations, enabling you to select and implement the best custom battery solution. As technology advances, the demand for custom batteries will continue to grow, driving further innovation in battery technology. For you, choosing the right custom battery requires careful consideration of efficiency, longevity, weight, safety, size, conductivity, and durability, ensuring optimal performance and reliability in your specific application.

Kamada Power is a leading custom lithium battery manufacturers in China. We provide custom lithium ion battery manufacture services, custom battery pack manufacture services. Kamada Power excels in delivering oem battery that meet diverse needs across industries, ensuring high performance, reliability, and safety.

Our expertise includes:

Customized Professional Knowledge: From design to manufacturing, Kamada Power specializes in creating precise lithium battery solutions tailored to meet specific customer specifications, whether for high-energy applications, portable electronics, or industrial equipment.

Quality Assurance: Committed to excellence, Kamada Power adheres strictly to quality standards (ISO), utilizing advanced manufacturing technologies to ensure batteries consistently exceed performance and durability expectations.

Customer-Centric Approach: At Kamada Power, customer satisfaction is our top priority. Our team collaborates closely with clients throughout the design and production process to ensure each custom battery solution meets stringent requirements and surpasses industry standards.

A lithium battery pack consists of 4 main parts, they are:

1 Battery Cell (cylindrical battery cell[like ], prismatic Cell [lipo and lifepo4 cell], Pouch cell[like lipo ] )

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2 PCM or BMS : it’s used for battery management, common functions like short-circuit protection, over-charge protection, over-discharge protection, over-current protection, NTC.  Monitor battery status like SOC[State of charge], SOH[State of health], SOP[State of power],  Communication with the battery with CAN protocol.

3 Battery Enclosure: the enclosure could be PVC wrapped, plastic enclosure or metal enclosure. PVC is the most commonly seen type enclosure as it almost doesn’t require any MOQ.

4 Connector: the connector is a very important part of a battery pack although it’s not the top concern. Some connectors are still the expensive expense of the total battery cost.

In the next part, we are going to explain them in detail.

1 Battery Cell

For lithium battery cell, we want to explain in detail from two perspectives: Cell Format and Battery Material.

A Battery Cell Format:

From a Cell format perspective, the lithium battery can be divided into 3 categories: Pouch cells, Prismatic cells, and Cylindrical cells.

Prismatic or pouch cells are normally referred to as lipo cells, they are widely used electronic devices, almost all our portable devices are equipped with these types of cells, they are lightweight and don’t cause explosion, they are also widely used in RC Helicopters and Quadcopter, the Cons is they might need higher MOQ like 3k or 5k units per order.

Cylindrical Cells like or is the most used cells for battery packs as you can source easily from the market for any types of cells at any pricing from 0.5 USD to 4 USD per cell. So such battery cells, it usually doesn’t need so much MOQ but space is limited as it’s cylindrical.

B Battery Components:

Different Factories will have different components of battery material, which is core to each battery cell maker, but Raw Materials have great pricing difference, some battery cells are can get mah in capacity, but they are cheap because they sacrifice life circle or let’s say performance, for normal cells they go 500 circles but for some cells whatever you test with any testing machine, they rated mah, but they will die much sooner as they have life expectancy like 300 circles.

Another important issue is there are two types of cells, capacity-focused cells and discharge-focused(high drain) cells, from our experiences, some would try to use the Capacity-focused cells to battery packs that may require High-discharge(high drain) cells like balance scooters.

Related News: My hoverboard EXPLODED under my feet Video

The Reason is simple too: the capacity-focused cells are usually cheap then discharge-focused(high drain) cells. but for devices like balance scooter, they might require C rate like 3-5C which is the Maximum of Capacity-focused cells but this is just the normal discharging rate for discharge-focused: in other words, the capacity focused cell(0.2-3C) will have problems of sudden death or explosion because they are running with max C rate all the time while the discharge-focused battery cell can easily handle such C rate requirement(5C-20C).

Takeaway: there is almost no way to define which is capacity-focused cell and which is a discharge-focused cell, they are also at the hands of the manufacturer. You need to test on your own.

C Battery Grade: Battery cells are Graded with A B C or further into A+ A- B+ B-. Let’s still take Samsung mAh Cell production for example,for each batch of mass production, before each cell goes to market, there will have a final process of Grading: for battery cells with capacity mah and same life circle like about 500 circles will be labeled Grade A; battery cell with less than mAh will be labeled grade B, battery cell with life circle less then 300 will be Grade C ( important: all above numbers are just examples only and do not apply to actual production and testing)

Why does this happen? it’s Simple: not each cell is produced at exactly mAh and 500 life circles: some would mAh, while some would mAh, although battery cell maker like Samsung has high production control on cell performance, they simply can’t avoid such things to happen.

Battery cells are therefore divided in to A, B, C,D, according to the capacity, battery life circle and sometimes appearance.

Sadly enough, there is no industrial standards of what is Grade A and what is Grade B, the Grade standards vary from each manufacturer. Therefore, we can say, The So-called Grade A cell is almost  SIMPLY a marketing Slogan, which is not much use but simply for promotion. But Branded cell take it more seriously, based on this, please always choose branded cells.

Important Takeaway: for battery packs more then 4 cells, if the battery cell are not the same grade A cells, there is high chances of shorter life or even explosion.

Related: Wikipedia Battery Balancing

Actually this is not trying to scare you, check any post on Google for battery balance and you will know the truth: suppose we are charging 4 cells mah,mah,mah,mah, let’s imagine if the mah is charged full already, but the charger is still charging as there is mah out there that don’t have enough juice. When the charging goes on, the battery has high chances of catch in fire or explosion (what if the mAh gap is even bigger, you can imagine the result: Disaster Or Nightmare)

Related: what if you are buying Fake Scam batteries , if you are buying fake Samsung or Sony cell simply because you want a cheap offer even less then any Chinese cells, chances are you are not a price killer, you just bring the nightmare to your customer as well as your company. 

A boom will let all go to nothing, you don’t want Samsung Note 7 Recall story happen to you, don’t you? Even Samsung suffered a lot from it, what about you? Disappear or Go to Jail?

D Business Type:  for most of the buyers, they want to buy directly from battery cell maker, and they insist to deal with battery cell maker only. This, actually, doesn’t make much sense. If you are reading this post, we suggest you to focus on the professionalism of the supplier you are talking to rather then trying to guess it’s cell maker or not.

Confused? Let’s go on to explain more.

Let’s Start with a simple question: who is the best manufacturer of lithium cells/packs? SAMSUNG, LG, SONY, PANASONIC, just name it,  but why don’t you deal with them?

If you contact Samsung, you would end in a slap your face as they want MOQ of 500k units per order.

Big Slap.

This is the same as many of Chinese cell maker, they don’t care your order at all. if they care, they die. Why? it takes half a day to let the cell maker machine to adopt a new model and finish your order in 30 minutes, will they do it?

BIG NO!

This is what they want: they want their machine to go 24/7, the cell maker, if not in high-end series, got only 10% in profit. They can make money only when they go 24/7.

Feel frustrated not dealing with cell maker directly? No, actually you are dealing with a third or fourth trader if not fifth trader/manufacturer.

Let’s back to the Samsung cell: if pack manufacturer can’t meet 500k units per cell per type(not for one month but for ongoing several months or years), they have to buy from traders!

Second-hand trader? You have the answer in your mind, don’t you?

The company is the world’s best LiFePO4 135Ah Lithium Battery supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.