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Custom Battery Design & Production Services

Epec Engineered Technologies designs, develops, and manufactures custom battery power solutions, supporting both product development and high-volume production of batteries, chargers, and battery packs with embedded BMS control.

With decades of operational excellence and an ISO9001:2015 production facility outside of Boston, Mass., plus strategic global manufacturing locations, Epec supports cost-effective, high-volume programs with in-house design, tooling, programming, regulatory, and test capabilities.

We offer designs for both primary and secondary chemistries to include, alkaline, NiMH, NiCd, primary lithium, and the latest lithium-ion or lithium-polymer batteries. Our goal is to offer full battery design support to help create a custom pack with optimal size, capacity, voltage, and operating temperature range to meet the many varied application demands.

At a Glance:

Custom battery pack design and production: Turn-key development and manufacturing of batteries, chargers, and battery packs with embedded BMS control, supported by in-house design, tooling, programming, regulatory, and test capabilities.
Broad chemistry and system expertise: Design support for primary and secondary chemistries, including alkaline, NiMH, NiCd, primary lithium, lithium-ion, and lithium-polymer, with guidance on size, capacity, voltage, safety circuitry, fuel gauging, and operating temperature range.
Proven team and production infrastructure: More than 70 years of operational excellence, an ISO9001:2015 production facility outside of Boston, Mass., global manufacturing locations, and a battery team with decades of experience across military, medical, industrial, and high-volume consumer applications.

Proven Innovative Battery Pack Solutions

Epec Engineered Technologies is an experienced designer, developer, and manufacturer of innovative battery power solutions. With more than 70 years of operational excellence, we have built a state-of-the-art ISO9001:2015 production facility outside of Boston, Mass., along with strategic global manufacturing locations to provide cost-effective, high-volume production. Epec manages complex customer programs with a stable of in-house design, tooling, programming, regulatory, and test capabilities.

Design & Production Services

We provide full turn-key services in product development and production of batteries, chargers, and battery packs with embedded BMS control. Our design support spans both primary and secondary chemistries, including alkaline, NiMH, NiCd, primary lithium, and the latest lithium-ion or lithium-polymer batteries.

Our goal is to help create a custom pack with optimal size, capacity, voltage, and operating temperature range to meet varied application demands.

Early Design Guidance

At Epec Engineered Technologies, we provide early design guidance and design services in the following areas:

Battery chemistry selection, including lithium-ion, lithium polymer, lithium iron phosphate, nickel metal hydride, alkaline, and some sealed lead acid.
Battery charger selection/design, whether standard off-the-shelf or a complete custom-developed design.
Battery fuel-gauge suggestions based on application, including the latest in TI products and software.
Battery safety circuitry recommendations, whether standard for basic lithium chemistry protection or custom developed to support specific requirements.
Battery construction suggestions, from chemistry and cell selection to BMS designs and enclosure recommendations, with design development.
System architecture guidance.
Regulatory guidance, with requirements managed by Epec, including UN, UL, and IEC certifications.
Production test equipment that can be custom-designed and developed to support low- to high-volume projects.

Custom Battery Design and Production Services

Portable Power Design

We support portable power design with mechanical and electrical engineering capabilities that align battery pack design decisions with manufacturability, test, and production needs.

Mechanical Engineering Support to Include:

Plastic design with 3-D modeling.
SLA prototypes and polyurethane quick-turn molds to support prototype development and low-volume projects.
Production tooling design, including ultrasonic weld and injection molding capabilities to support high-volume production.
Custom labels and overlays, including custom features, adhesives, colors, embossing, and various materials to meet UL standards.

Electrical Engineering and PCB Design and Layout Support to Include:

PCB Design optimization.
Schematic capture.
Gerber files.

Design Deliverables Commonly Supported:

PCB layouts.
Schematics.
Gerber files.
Complete BOM (bill of materials).
Housing material recommendations and design support.

Custom Battery, Battery Charger, and Fuel Gauge Design to Include:

Epec supports custom battery, battery charger, and fuel-gauge designs based on application needs. This includes selection or design approaches that range from standard off-the-shelf choices to complete custom development, along with guidance on fuel gauging and safety circuitry appropriate to the chemistry and requirements.

Embedded Firmware Development

Epec supports embedded firmware development for battery-related system interfaces. Embedded firmware is the flash memory chip that stores specialized software running in a chip in an embedded device to control its functions. Support can also include custom battery and customer system interface development.

Automated Production Test Equipment Design and Development

Epec supports production test equipment development, including custom-designed solutions that can scale from low- to high-volume projects. This testing support aligns with Epec’s broader in-house regulatory and test capabilities used to manage complex customer programs.

Battery Team Experience

We have key team members who have been active within the battery and battery-charger industry since 1996. Our battery team has more than 22 years of experience in military, medical, industrial, and high-volume consumer industries, providing a distinct advantage when developing and qualifying battery designs for use in these environments.

Epec’s experience includes pioneering the development of custom safety circuits and battery chargers for the Li-sulfur chemistry. We also have extensive experience developing safety circuits, fuel gauging, and battery chargers for Li-ion and Li-polymer chemistries, and our team has received numerous patents in this area of work.

Frequently Asked Questions

Quick Links

What does Epec provide for custom battery pack design and production?
Which battery chemistries are supported?
Can Epec help with charger selection or custom charger design?
What guidance is available for fuel gauging and safety circuitry?
Does Epec provide mechanical engineering support for enclosures and tooling?
What electrical engineering and PCB-related support is included?
What experience does Epec’s battery team bring to regulated or demanding industries?

What does Epec provide for custom battery pack design and production?

Epec provides turn-key services for product development and production of batteries, chargers, and battery packs with embedded BMS control. Support includes in-house design, tooling, programming, regulatory guidance, and test capabilities used to manage complex customer programs.

Which battery chemistries are supported?

Design support covers both primary and secondary chemistries, including alkaline, NiMH, NiCd, primary lithium, and the latest lithium-ion or lithium-polymer batteries. The page also lists lithium iron phosphate and some sealed lead acid as chemistry options considered during selection.

Can Epec help with charger selection or custom charger design?

Yes. The page describes support for battery charger selection/design, whether standard off-the-shelf or a complete custom-developed design, and also notes experience developing battery chargers for multiple chemistries.

What guidance is available for fuel gauging and safety circuitry?

The page describes battery fuel-gauge suggestions based on the application, including the latest in TI products and software, and safety circuitry recommendations that can be standard for basic lithium protection or custom-developed for specific requirements. It also notes experience in safety circuits and fuel gauging for Li-ion and Li-polymer chemistries.

Does Epec provide mechanical engineering support for enclosures and tooling?

Yes. The page lists plastic design with 3-D modeling, prototyping support (SLA prototypes and polyurethane quick-turn molds), and production tooling design, including ultrasonic weld and injection molding capabilities. It also includes custom labels/overlays and materials to meet UL standards.

What electrical engineering and PCB-related support is included?

The page lists PCB design optimization, schematic capture, and Gerber files, and also includes PCB layouts, schematics, Gerber files, and a complete BOM (bill of materials). Housing material recommendations and design support are also included.

What experience does Epec’s battery team bring to regulated or demanding industries?

The page states key team members have been active in the battery and battery-charger industry since 1996, and the battery team has more than 22 years of experience in military, medical, industrial, and high-volume consumer industries. It also notes pioneering work on Li-sulfur safety circuits and chargers, extensive Li-ion/Li-polymer safety and charger experience, and numerous patents.

Need Help Designing a Custom Battery Pack?

Contact Epec to help optimize your battery pack design, from early design guidance through turn-key product development and high-volume production.

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