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Battery & Battery Pack Capabilities

Epec Engineered Technologies partners with customers to design and build custom battery packs that meet or exceed defined electrical, mechanical, and regulatory requirements. Engineering support covers cell selection, battery management system (BMS) design, enclosure development, and production readiness to deliver a quality, application-specific battery solution.

Epec designs and manufactures custom battery packs and complete power management systems tailored to specific application requirements. Capabilities span primary and rechargeable batteries, smart battery packs, enclosure design, and regulatory compliance. Early alignment on chemistry, voltage, capacity, and certification requirements is critical to achieving cost-effective and timely production.

By providing the entire power management system, rather than individual components, Epec reduces development risk, shortens time to market, and minimizes total system cost.

At a Glance: Battery Pack Capabilities

End-to-end battery pack expertise: Epec designs and manufactures custom battery packs and complete power management systems, covering cell selection, BMS integration, enclosure design, and production readiness.
Broad chemistry and configuration support: Capabilities span primary and rechargeable batteries across a wide range of chemistries, voltages, capacities, and enclosure types, including smart battery packs with SMBus communication and cell balancing.
Speed, quality, and compliance focus: Proven designs, rapid prototyping, integrated supply chain management, and ISO-certified manufacturing help customers reach production faster while meeting regulatory and application requirements.

Our Battery Capabilities Include

Epec supports a wide range of battery technologies and integration levels, from basic packs to smart battery systems with embedded electronics.

Primary Batteries (Non-Rechargeable)

A primary battery is a galvanic cell designed for single use and disposal. The electrochemical reaction is not reversible, making recharging impractical.

Chemistries include:

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

Applications include:

Radios
Toys
Photo-Flash Applications
Watches
Hearing Aids

Rechargeable Batteries (Secondary)

Rechargeable batteries, also called secondary cells, are designed to be charged, discharged, and reused multiple times.

Chemistries include:

Nickel metal hydride (NiMH), including passive safety devices for short-circuit and overheating protection
Nickel Cadmium (NiCD)
Lead Acid Batteries
Lithium-ion batteries (cylindrical sizes including 10440, 14430, 14500, 18500, 18650, 26650, 38120, 40160)
Lithium polymer batteries with a wide range of pouch sizes
Lithium iron phosphate (LiFePO4) batteries in cylindrical, polymer, and prismatic formats, offering lower energy density and longer life cycles

Applications include:

Medical devices such as defibrillators
Cameras and meters
Calculators
Portable and low-power devices
Watches

Custom Battery Packs

Custom battery packs allow performance to be closely matched to application requirements. Epec supports nearly any voltage or capacity requirement, with chemistry selection tailored to electrical, mechanical, and regulatory needs.

Design options range from basic battery packs to smart (SMBusenabled) systems and may include:

High or low-capacity configurations
Board-level charging or external charging
Cell balancing and protection circuitry
Plastic or metal enclosures

Using a single supplier for design, assembly, and power management integration improves coordination and reduces overall development cost.

Smart Battery and Power Management Capabilities

Epec designs smart battery packs that integrate electronics for monitoring, protection, and system communication.

Smart battery capabilities can include:

Battery management system (BMS) design
Integrated fuel gauges
Communication protocols such as SMBus and CAN
Low or over-temperature alarms
Overvoltage, overcurrent, and temperature protection
User data logging
Cell balancing and matching

These features support safety, reliability, and certification requirements across demanding applications.

Enclosure, Protection, and Integration

Mechanical design is a core part of custom battery pack development. Epec provides inhouse engineering support for enclosure and protection requirements.

Mechanical and integration capabilities:

Custom enclosures in plastic or metal
Venting considerations for regulatory testing
Potting, encapsulation, and shrink wrapping
Thermostats, fuses, thermistors, and protection circuitry
Heaters for subfreezing operating conditions
Cable and connector assemblies with custom terminations

Supply Chain and Inventory Management

Flexible inventory management programs are available to support production and fulfillment needs. Options include Kanban, blanket orders, and consignment.

Epec manages inbound and outbound logistics, consolidates inventory across the supply chain, and can deliver on a just-in-time basis. These capabilities reduce inventory on customer floors while improving responsiveness to demand changes.

Quality, Compliance, and Certification

All manufacturing facilities are certified to ISO9001:2008, ISO9001:2015, ISO14000, and are ITAR registered. Quality systems are based on IPC and military specifications, with documented calibration and inspection controls.

Only first-class, traceable materials are used. Extensive testing and inspection are performed throughout manufacturing to ensure each battery pack consistently meets or exceeds specifications.

Regulatory support includes DOT, IATA, IEC, and UL testing and approvals.

Helping Customers Get Products to Market Faster

Epec maintains a large library of proven battery pack designs to accelerate development. This experience enables rapid prototyping and a faster transition into production without relying on improvised or low-quality component assemblies.

Internal capabilities include:

Rapid prototyping with 3D printing and internal machining
IPC-certified assemblers
Assembly drawings provided prior to manufacturing
DFMEA and PFMEA processes
Inhouse HALT and HASS testing

Experience spans medical, military, and aerospace applications with associated regulatory requirements.

Frequently Asked Questions

Quick Links

What should I know about BMS?
When would I use cell balancing?
What are considerations for enclosure design?
What does capacity mean in this context?
What does voltage mean in this context?
What should I know about SMBus?

What should I know about BMS?

A battery management system monitors and protects the battery by controlling voltage, capacity usage, temperature limits, and safety functions required for compliance.

When would I use cell balancing?

Cell balancing is used in multicell battery packs to ensure consistent performance and reliability across all cells.

What are considerations for enclosure design?

Enclosure design must account for venting, protection circuitry, regulatory testing, and the operating environment. Material choice may be plastic or metal, depending on requirements.

What does capacity mean in this context?

Capacity defines how much energy the battery pack can store and directly impacts runtime for the application.

What does voltage mean in this context?

Voltage must match the application’s electrical requirements to ensure proper operation and compatibility with charging and control electronics.

What should I know about SMBus?

SMBus enables communication between the battery pack and the host device, supporting monitoring, control, and diagnostic functions.

What Capabilities Are You Looking For?

Work with Epec’s engineering team to define your battery requirements and develop a custom, production-ready power solution that aligns with performance, cost, and compliance goals.

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