Battery Pack Lead Times: Prototypes and Production Orders

As an approved battery pack assembler for some of the top tier manufacturers like Panasonic, A123, LG, and Samsung, our development process is streamlined to be able to begin the battery pack design and prototypes without delay. Whether your application requires a lightweight battery with high energy density, low auto-discharge, significant power peaks and a long life, or even a very unusual shape or waterproof case, we have a library with hundreds of designs that we can take from to help speed up the process.

We have designed various handheld instrumentation, military, aerospace, industrial, and medical devices using these suppliers and understand the emphasis on safety.

Our battery system architecture experts, mechanical engineering team, and production staff will help you define your needs and advise you in terms of best practices to ensure excellent reliability and safety of custom lithium-ion battery packs. Our designs incorporate all the protection devices required and recommended by our partners for the use of lithium-ion batteries under the right conditions to optimize the capacity, service life, and performance of the battery pack.


Custom Battery Pack Lead Time to Market

The times mentioned below are subject to change based on complexity of the particular custom battery pack that is being design and manufacturer. Our objective with this information is to provide a realistic overview of what the true timing of developing a 100% custom battery pack will be. Many competitors tell you that they can cobble together off-the-shelf components in a few weeks to get you a working model, but that is not a very safe or reliable way to test out the product specifications in your application.

While we have done prototypes in very short periods of time, it is not responsible to try and communicate unrealistic lead times via this page without first seeing the requirements of every application. You may also want to see our battery pack development timeline process and custom battery pack lead times blog posts for additional information, but below we’ve listed some general outlines.


Battery Pack Timelines


Alkaline:

  • Design & Basic Prototypes - 15 working days
  • Production Tooling Fixture Timeline - 4 to 6 Weeks
  • Production Lead Time Once Design is Finalizes - 20 to 25 working days
  • Specialty Potting Materials and Tooling may add additional lead time

Ni-MH and Ni-Cd Chemistry:

  • Design & Basic Prototypes - 20 working days
    • This lead time may be extended as many NiMH designs need to include protection circuitry developed for short circuit and overheating protection.
  • Production Tooling Fixture Timeline - 2 to 4 Weeks
  • Production Lead Time Once Design is Finalizes - 20 to 25 working days
  • NiMH Transportation Certification - 2 Weeks (10 samples required)

Lithium Battery Lead Times:

The timelines for the development a production of batteries using any of the lithium chemistries will be a function the complexity of the pack. Everything from IC lead times (Texas Instruments, Analog Devices, Seiko) to a specification that has very tight tolerances that require thousands of lines of code to be written can affect the lead time. But a basic overview is:

  • Electrical Design Timeline - 4 to 6 weeks
  • Battery Prototypes - 4 to 6 weeks (pending cell availability)
  • Mechanical Design - 4 to 6 weeks
  • Software/Firmware Design - 4 to 5 weeks
  • 3D Printing Modeling Process - 5 to 10 Days
  • Injection Molded Enclosure Tooling - 8 to 10 weeks
  • UN38.3 Transportation Certification - 6 to 8 Weeks (17 Samples Required)
  • UL/IEC Certification - 6 to 8 Weeks (50 Samples required)
    • In many instances these test can only be submitted once the UN 38.3 has been approved
  • Production and Test NRE's - 6 to 8 weeks

Additional Capabilities:

  • Design Capabilities: New Bedford MA, Asia
  • Prototype Capabilities: New Bedford MA, Asia
  • Injection Molding Capabilities: US and Asia
  • Production Capabilities: New Bedford MA, Asia
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