Battery & Battery Pack Capabilities

Epec Engineered Technologies works with our customers to design and build custom battery packs to exceed their requirements. Our engineering team will help the design team select the best cell type and size for each application, along with all the other mechanical and electrical parameters needed to produce a quality battery product.

Our custom battery pack design and assembly can provide a smart (SMBus) or a basic design, with low- or high-capacity specifications, with or without board charging or cell balancing and all different types of enclosures. Having one company that you can count on to provide the entire power management system will improve your time to market and will minimize your overall development cost as one company can be simultaneously working on all facets of the custom battery packs.

Not every battery chemistry provides the same performance, so our engineering team will work with you to determine which chemistry is best for your needs. We can deliver custom battery pack solutions in nearly any voltage or capacity you may require and in the right chemistry for your application. Along with ensuring regulatory compliance for battery pack designs including UL standards, IEC standards, national and international regulations, and more, they need to be understood at the earliest point in the process to ensure that all design decisions are being made with the end regulatory compliance in mind.

We have a substantial library of existing battery pack designs that we use the experience from to help quickly develop and produce a custom battery pack solution, which allows our customers to quickly get to a prototype and into production. Epec Engineered Technologies specializes in custom-built battery packs that exceed your product’s exact specifications. Many companies try to cobble together low-cost, off-the-shelf components in order to reduce the battery cost, but this strategy has proven to not provide the safety and quality that our demanding customers require.

Custom Battery Packs Capabilities



Our Battery Capabilities Include

Primary Batteries (Non-Rechargeable):

Defined as a battery (a galvanic cell) that is designed to be used once and discarded, and not recharged with electricity and reused like a secondary cell (rechargeable battery). In general, the electrochemical reaction occurring in the cell is not reversible, rendering the cell unrechargeable.


Chemistries include:

  • Lithium (high impedance for low-drain applications)
  • Alkaline
  • Zinc Air Cells
  • Aluminum Air Cells

Applications include:

  • Radios
  • Toys
  • Photo-Flash Applications
  • Watches
  • High-Drain Applications
  • Hearing Aids
  • Electric Vehicles
  • Pacemakers
  • Defibrillators
  • Watches
  • Meters
  • Cameras
  • Calculators
  • Portable and Low-Power Devices

Rechargeable Batteries (Secondary):

Defined as a storage battery, or secondary cell (archaically accumulator) is a type of electrical battery that can be charged, discharged into a load, and recharged many times, as opposed to a disposable or primary battery, which is supplied fully charged and discarded after use.


Chemistries include:

  • Nickel Metal Hydride (NiMH)
    • Extensive experience and design library in developing passive safety devices for protection against short circuits and overheating in NiMH batteries
  • Nickel Cadmium (NiCD)
  • Lead Acid Batteries
  • Lithium Cells
    • Lithium-Ion Batteries: - Sizes 10440, 14430, 14500, 18650, 18500, 26650, 38120, 40160
    • Lithium Polymer Batteries: Hundreds of pouch battery sizes with minimum production quantities.
    • Lithium LiFePO4 Batteries: Cylindrical, LiFePO4 Polymer, and prismatic cells (lower energy density, better power density, and longer life cycles)

Applications include:

  • Calculators
  • Digital Cameras
  • Laptops
  • Flashlights
  • Medical Devices (E.G. Defibrillators)
  • Electric Vehicles
  • Space Applications
  • Cellular Phones
  • Camcorders
  • Emergency Backup Lighting
  • Power Tools
  • Portable Devices
  • Electric Vehicles

Custom Battery Packs:

  • Design Capabilities (all cell chemistries available in battery packs)
  • Smart Battery Packs - can include:
    • Integrated fuel gauges
    • Integrated circuits
    • Communication protocol (SMBus, CAN, and others)
    • Low/Over Temperature and Short Circuit Alarms
    • Over Voltage, Current, or Temperature Protection
    • User Data Logging
  • Cell Balancing and Matching
  • Chargers - Both on-board and separate, connected, and inductive.
  • Cable/connector assembly and custom terminations
  • Thermostats, fuses, thermistors, and protection circuitry
  • Custom enclosures (plastic or metal) - in-house engineering team
  • Potting and shrink wrapping
  • Encryption coding
  • All cell form factors including coin cells
  • Tight tolerance encapsulation under vacuum
  • Heaters when batteries need to operate in sub-freezing conditions
  • DOT, IATA, IEC, and UL testing and approval
  • Assembly drawings provided prior to manufacturing
  • Design Failure Mode Effect and Analysis (DFMEA) and Process Failure Mode and Effect Analysis (PFMEA) processes
  • Rapid internal prototyping capabilities, including 3D printing, IPC Certified assemblers, and internal machining capabilities (www.metalcraftmachining.com)
  • Experience in medical, military, and aerospace applications and regulations
  • In-house HALT/HASS testing

Supply Chain Management

Flexible inventory management programs are available (Kanban, blanket orders, consignment). We manage inventory and handle inbound and outbound logistics, while making deliveries when and can even provide customer fulfillment when needed.

Epec goes beyond the traditional distributor model with superior inventory acumen and proven operational excellence. We lower total system costs by consolidating inventory across the entire supply chain, including taking inventory off customers' floors. Epec has a core competence in inventory and logistics management that can help customers control inventory levels and expenses and can deliver to customers on a just-in-time basis.

All our manufacturing facilities are ISO9001:2008, ISO9001:2015, ISO14000 certified, and ITAR registered. Our Quality Assurance Department has an inspection system based on IPC and military specifications. We have documented control and calibration systems for all gauges and test equipment. In addition, we insist that only first-class materials with traceability go into our product. More importantly, to assure the product we ship, meets, or exceeds your specifications consistently, an extensive series of tests and inspections are carried out at each step of the manufacturing process.


Helping Customers Get Their Products to Market Faster

Epec Engineered Technologies has the engineering team and resources to collaborate with our customers to develop custom designed batteries to support just about any industry. Our experience has helped many customers to design batteries, including chemistry selections, appropriate cell models to meet specific power requirements, BMS designs, cell balancing, and fuel gauging for the pack electronics to meet all safety and certification requirements. Our mechanical team has experience with enclosure designs to provide best practices for required venting conditions, and meeting industry regulatory testing as well. We apply the same support efforts designing custom chargers for our battery customers.


What Capabilities Are You Looking For?

Ready to transform your power needs into engineered solutions? Choose Epec's custom battery packs for quality, speed, and seamless integration.

Request a Quote   Request Design Support   Request More Information
Celebrating 70 Years of Manufacturing Excellence   Learn More →
America's Oldest. A History of Innovation.

Over the past 70 years, the electronics manufacturing industry has changed dramatically as the industry continues to adapt to evolving demands and technology. Epec is at the forefront of innovation, with the expertise and agility to move at the speed of today’s businesses. At Epec, the customer comes first, and everything we do must be put through that filter. Whether it is developing e-commerce platforms to make it easier to work with us or creating a new product introduction (NPI) process that helps our customers get to market faster, we must focus on building the new. By doing that every day, and by always making the customer our top priority, we plan on being here for another 70 years and then some.

Learn more about our 70 year story →





Celebrating 70 Years - Epec Engineered Technologies