What Information Do You Need to Provide for Custom Lithium Battery Packs?

Custom lithium battery packs are essential for powering a wide variety of devices, from smart electronics to medical equipment, industrial tools, and IoT systems. But to design the right lithium battery pack for your project, we need detailed information from the very beginning.

Here’s a complete guide to the 8 critical items you should provide when requesting a custom lithium battery solution.

1. Country/Region

Different countries have different battery safety certifications, shipping standards, and voltage regulations. Knowing the destination helps us ensure compliance with:

UL, UN38.3, CE, IEC standards
Regional shipping classifications
Local power compatibility

2. Application Scenario

What type of device will the battery power?
Examples include:

Smart meters, electronic toys
Portable medical equipment
Handheld scanners, POS terminals Example: “Used in a CCC-certified toy car” or “for a barcode scanner”

This helps us determine safety level, cycle life needs, and design constraints such as shape or temperature resistance.

3. Required Voltage and Capacity

Please provide:

Nominal voltage: e.g. 3.7V, 7.4V, 11.1V
Capacity: e.g. 2600mAh, 5200mAh, etc.

Example: 11.1V 2.6Ah (3S1P)

If you’re unsure about capacity but know how long the device should run, we can estimate it for you (see section 5).

4. Battery Pack Dimensions

Tell us the maximum space available inside your device for the battery. Dimensions should include:

Length × Width × Height (mm)
Example: 19 × 57.5 × 70 mm

This is crucial for selecting a matching cell size and structure.

5. Load Conditions

Two types of data are helpful:

Maximum continuous current: e.g. 3A
Estimated runtime: If you know the current but not the capacity, tell us how long the battery should last. We’ll calculate the required capacity for you.
Example: “Device uses 2A and needs to run for 3 hours.”

6. Terminal Wire and Connector Requirements

Please specify:

Wire type: e.g. UL1007 24#
Wire length: e.g. 100mm (± tolerance)
Connector type: e.g. PHR-2P, JST, Molex
Pin order: If applicable, provide a wiring diagram

Example: “PHR-2P reverse, 3-pin connector with custom wiring sequence”

7. Appearance or Enclosure Requirements (If Any)

Let us know if your battery pack needs:

A plastic or metal housing
Waterproofing (e.g. IP65 level)
Special labeling, sticker, or shape
Custom mold drawings (PDF or CAD preferred)

This ensures mechanical safety and visual integration into your device.

8. Operating Temperature and Humidity

Please indicate the temperature and humidity your battery will face during:

Operation
Storage
Charging

Example: Working at 0–45°C, storage at -20–60°C, ≤85% RH non-condensing

High or low temperatures may require special cell selection, heating films, or reinforced BMS protection.

Quick Reference: Custom Lithium Battery Checklist

No.	Information to Provide	Example Input
1	Country / Region	USA / Germany / Japan
2	Application	Smart lock / Toy / Sensor
3	Voltage & Capacity	11.1V 2600mAh
4	Pack Dimensions	19 × 57.5 × 70 mm
5	Load Current or Runtime	3A max / 2A for 3 hours
6	Wire & Connector Specs	UL1007 24#, 100mm, PHR-2P
7	Enclosure / Waterproofing	PVC shrink + IP65
8	Temperature & Humidity Range	0–45°C, <85% RH

Conclusion: The More You Provide, the Better the Design

The more accurate and detailed your information, the more precise and efficient our design will be. Whether you’re prototyping a new IoT device or upgrading your power system, having a complete requirement list helps us recommend the most suitable cell chemistry, protection circuit, and pack structure.

Ready to start your lithium battery customization project?
Contact our engineering team now—we’ll help you design the right pack from cell to connector.