Key Questions to Ask When Ordering Customized battery systems

Sep. 08, 2025

Key Considerations When Specifying a Custom Battery Pack

Applications may require custom battery packs when off-the-shelf packs cannot meet their requirements. The battery packs may need to use specific materials or have certain power, charge, or safety feature requirements.

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Other times, you must arrange for specific testing and certifications based on the industries that will use the device. There are several key considerations to consider when you are designing a customized battery pack.

Determining Power Requirements

Power requirements for battery packs focus on several key aspects: how much power the battery pack holds, how fast it will give power to the application, and how long will the application run before the batteries need to be recharged.

We determine the power requirements (the speed of drawn-out power by using watts (W) and how much energy is stored in the battery cell by using watt-hours (Wh). Basically, the application will require a certain number of watts to run for a specific number of hours.

So, you have a device that is rated to draw out 50 watts of power per hour. You want this device to run for 4 hours. You would take the number of watts (50) and multiply that by the length of time the battery will operate (4 hours).

The equation would be 50 watts x 4 hours = 200 watt-hours (Wh). Now you know that the battery's capacity should accommodate 200Whs.

Another equation you can do is figure out how long the battery will operate when you are connecting several devices to a single battery pack. If you already know the capacity of the battery pack, you can take the stated capacity of the battery (200Wh) and divide it by the total watts from the connected devices.

For this example, you have one device that has 50W and another that has 10W for a total of 60W. The equation to determine the battery's operation time would be 200Wh battery capacity/60W = 3.33 hours.

Determining the requirements for the battery power and capacity for the application will allow you to figure out the number of batteries that will be required for the pack. It will allow you to narrow down your choices about the type of battery chemistry to use as well as how to design the enclosure.

Calculating Charge Requirements

There are both custom chargers and off-the-shelf chargers for applications. Best practices dictate that if you are obtaining a custom battery pack, you want to supply a charger that is designed for that specific pack. This practice ensures that the charger will provide the right amount of energy without overcharging or undercharging the battery pack to avoid damage and a loss of capacity.

Battery charging is based on voltage (which is the unit of current for every cell in the pack) and how much power it pushes for the required application. Unlike capacity and power, the voltage of the battery is consistent. It never changes based on the chemistry of the cell. Each chemistry has a nominal voltage, such as 3.6 volts for lithium-ion batteries, 1.2 volts for NiCad, and 1.4 volts for NiMH. Keep in mind that battery chemistries can provide higher voltages for the applications than the nominal voltages are for the cells. So, a battery that is 3.6V can offer 4.2V for the device.

When it comes to designing a charger, you want one that can provide the required amount of voltage based on the number of batteries present in the pack. If you have 4 lithium-ion cells in a battery pack that offers 3.6 volts, you will determine this required charger voltage by multiplying 4 cells by 3.6 volts (3.6V x 4 cells = 14.4V). You need a charger that provides 14.4V for the battery pack.

Providing Safety Features

Safety features for battery pack design will depend on the type of battery chemistry that is present. Lithium-ion batteries have more unstable chemistries that could lead to thermal runaway, fires, or explosions. Many national and international regulations have requirements where a battery management system is necessary for lithium-based battery packs.

A battery management system (BMS) can offer temperature monitoring, current and voltage regulation, and thermal management. Additional safety features may be added to the BMS based on the environment where the application will be used, charging or discharging rates, vibrations, venting, and other factors.

Battery pack being manufactured with BMS and custom enclosure.

Another safety feature can involve cell balancing. Cell balancing ensures that some cells do not get discharged or overcharged more than others by redistributing the charge between cells (active balancing) or dissipating excess charge, so all the cells have the same SoC (passive balancing).

Designing Enclosure & Material Requirements

Battery materials focus on the actual construction of the battery, such as the materials used to create the anodes, cathodes, electrolytes, separators, and connections. The types of materials used will depend on the battery chemistry.

For example, anodes can be made from lithium, graphite, or silicon for lithium-based cells while alkaline batteries will have a zinc-powder paste-like gel. Separators usually consist of foam, and electrolytes may range from potassium hydroxide to lithium hexafluorophosphate. Internal connections may be designed with nickel strips. Care must be taken to ensure that the right materials are used based on the application and any stress or loads that could be experienced while the battery pack is in operation. There may be certain material requirements based on industry, such as military & defense or medical, that will have to be met. Other times, budgetary restraints may require a close look at whether lower-cost materials can be used while still providing a high-quality battery pack that fits the needs of the application.

The same care must also be taken for the design of the battery enclosure. Battery enclosures may be internally placed into the device, or have a separate compartment attached in another location. Some common designs include metal casings, shrink-wrap, or vacuum-formed plastic. Deciding on the enclosure will depend on how it will protect the batteries, how it will protect the user of the application, environmental hazards, and even appearance.

Certification Requirements for Marketing Purposes

Not every type of battery requires certification, except for lithium-based chemistries, while some manufacturers may need certifications based on industry requirements. Manufacturers may also seek out certification to market their products to the public by using this certification to show the high-quality production standards that are in place.

Battery pack with certification markings on the enclosure.

To determine whether your battery pack requires certification, and which certifications to get, will be based on the standards of the certifying organization. Some of the standard certifications come from UL, IEEC, and IEC testing that may require several battery packs that will undergo testing and testing costs.

Summary

Keep in mind that battery pack testing costs will vary based on the organization and the number of tested packs. Testing times can also vary from 4 weeks up to 12 weeks based on the organization. These factors can impact lead times to market and need to be considered in the overall design timeframe of the battery packs.

Key Takeaways

Key Factors to Consider When Choosing battery BMS Manufacturer

As battery technology continues to evolve, more and more businesses and industries are relying on battery management systems (BMS) to ensure the safe and efficient operation of their battery systems. When it comes to managing battery systems, it’s essential to choose the right batter BMS manufacturer. But with so many battery management system manufacturers out there, how can you identify the professional ones that will meet your needs?

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When it comes to choosing a battery management system manufacturer, there are several factors to consider to ensure that you’re getting a high-quality and reliable product. Here are some key factors to keep in mind, along with how Tritek Company excels in each area.

Quality Control Processes:

Battery management systems are an essential component of battery packs and battery modules, and their reliability is critical to ensuring optimal battery life and performance.

At Tritek Company, we recognize the importance of quality control processes in ensuring the reliability of our battery management system solutions. We use only high-quality materials and components, and our products undergo thorough testing to ensure that they meet or exceed industry standards.

During production, we use advanced manufacturing processes and state-of-the-art equipment to ensure that our products are built to the highest standards of quality and reliability. We also conduct extensive testing at each stage of production to identify and address any potential issues before they can affect the final product.

Finally, before shipping our battery management systems, we conduct final testing to ensure that they meet all performance specifications and are ready to perform in the field. With our rigorous quality control processes, Tritek Company is committed to delivering reliable and high-quality battery management system solutions that help to maximize battery life and performance for our customers.

Industry Experience:

BMS manufacturers with years of experience in the industry will have a deep understanding of the technology and be able to provide reliable and efficient solutions. They will also be familiar with common issues and know how to address them.

Tritek Company’s experience in the battery management system industry has given us a deep understanding of the various types of battery packs and modules, their different topologies, and the many benefits of using a distributed topology BMS. We understand the key role that a BMS plays in ensuring the optimal performance and safety of a battery pack.

Our experienced team of engineers has developed BMS solutions that can monitor important parameters such as state of charge, cell voltage, and temperature in real-time, providing insight into the battery’s state and enabling optimized battery performance.

Tritek’s BMS solutions support both centralized and distributed architectures, allowing for flexibility in battery pack design. Our distributed BMS solutions enable intelligence circuitry to be distributed across all the cells in the battery pack, ensuring that each cell is individually monitored and balanced. This approach provides several benefits, including increased reliability, lower cost, and improved safety.

In summary, Tritek Company’s extensive experience in the battery management system industry has enabled us to develop reliable and efficient solutions for a wide range of battery pack and module applications. Our BMS solutions provide critical monitoring and balancing functions for batteries of all sizes and can be tailored to meet specific customer requirements.

Technical Expertise:

Tritek Company’s team of experienced engineers has extensive experience in designing and developing BMS solutions for various applications, including lithium-ion batteries, battery packs, and energy storage systems. They have a deep understanding of lithium-ion battery technology, cell voltage, and battery cells, and are capable of designing BMS solutions that can monitor cell voltage and provide cell balancing.

Our BMS solutions incorporate cell monitoring circuitry that enables real-time monitoring of lithium-ion cells, allowing for optimized battery operation and extended battery life. Our engineers have designed BMS solutions for a variety of applications, including light electric vehicles, energy storage systems, and mobile phones, with each BMS solution tailored to meet the specific requirements of the application.

We have designed BMS solutions that can monitor the voltage of individual cells and other modules, allowing for the entire pack to be monitored and optimized for performance. Our BMS solutions incorporate a master module that provides centralized control and internal communication between the other modules, ensuring that the battery operates efficiently.

In summary, Tritek Company’s experienced team of engineers has the technical expertise required to design and develop high-quality BMS solutions for a variety of applications. Our BMS solutions incorporate cell monitoring and balancing circuitry, allowing for optimized battery performance and extended battery life.

Customer Support:

A professional BMS manufacturer will provide excellent customer support before, during, and after the sale. This includes answering questions, providing technical support, and addressing any issues that may arise. They should be responsive to your needs and provide prompt, helpful assistance.

Tritek Company is committed to providing excellent customer support. It has established a service center in Spain and is planning to open additional service centers in Germany and the United States. This demonstrates our commitment to providing prompt and helpful assistance to customers worldwide.

Product Warranty:

Look for BMS manufacturers that offer comprehensive product warranties to protect your investment and provide peace of mind. A good warranty should cover defects in materials and workmanship, as well as any issues that arise due to normal use.

Tritek Company offers comprehensive product warranties to protect customers’ investments and provide peace of mind. Its warranty covers defects in materials and workmanship, as well as any issues that arise due to normal use.

Compliance with Industry Standards:

It’s crucial to choose a BMS manufacturer that complies with industry standards such as ISO , CE, and UL. These certifications ensure that the manufacturer’s products meet quality and safety standards, and that they follow best practices in manufacturing and quality control.

The BMS produced at Tritek are compliance with global certification standards, such as EN:, CE, FCC, CB, UL, etc., demonstrating our commitment to quality and safety.

References and Testimonials:

Asking for references and testimonials from past customers is an excellent way to gauge a manufacturer’s reputation and track record. You can ask the manufacturer for a list of references, or look for online reviews and testimonials from other customers.

Tritek Company has a strong reputation in the industry and has received positive reviews and testimonials from many satisfied customers. Our commitment to quality, technical expertise, and customer support has helped us to build a loyal customer base.

In conclusion, choosing a professional and reliable BMS manufacturer is crucial for ensuring the success of your battery-powered devices. By considering the factors mentioned above and Tritek Company’s strengths in each area, you can make an informed decision and select a manufacturer that meets your needs. With our extensive experience, technical expertise, and commitment to quality, Tritek Company is an excellent choice for anyone looking for a reliable and high-quality BMS solution.

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