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Author: Sanket Doshi

How Custom Battery Packs Improve Product Performance

Introduction

In today’s fast‑moving world of portable electronics, industrial systems, medical devices, and IoT equipment, standard off‑the‑shelf batteries often aren’t enough. Performance demands in size, weight, discharge/charge profile, safety, and lifecycle are rising. That’s where custom battery packs come into play. By tailoring every aspect of the power source to the device and application, you unlock higher performance, longer life, and a competitive edge.

At Emerging Power, we specialise in custom‑designed battery packs combining advanced chemistries (like lithium‑ion and Li‑polymer), integrated management systems (BMS), and full regulatory testing to bring your product to market faster and stronger. 

In this article, we’ll explore why custom battery packs improve product performance and how Emerging Power delivers that difference.

Why Standard Battery Packs Fall Short

Off‑the‑shelf batteries are convenient and cost‑effective for many use‑cases, but they come with trade‑offs:

  • Limited flexibility in form factor: standard shapes may force compromise in device design, adding bulk or weight.
  • Sub‑optimal energy or power density for the exact application: you might oversize “just in case”, or undersize and suffer short runtime.
  • Generic safety, thermal, and charge/discharge profiles: high‑performance devices often need more stringent requirements.
  • Longer time to certification or ruggedisation when the pack wasn’t designed specifically for the product environment (e.g., medical, military, outdoor).

3. How Custom Battery Packs Drive Better Performance

Here are the key advantages of a custom battery pack design in improving your product’s performance:

  • Tailored Form‑Factor & Weight – When a battery pack is designed specifically for your product, you can optimise size, shape, weight distribution, and integration. This helps devices become slimmer, lighter, or more ergonomically designed, improving user experience, portability, and aesthetics.
  • Optimised Energy & Power Profile – Custom design allows you to match capacity (how much energy) and power (how fast you can deliver energy) exactly to the application’s load profile. For example, a device with bursts of high power but a light standby load benefits from a pack engineered for high discharge rather than just high capacity.
    Emerging Power emphasises working with “leading name‑brand cell manufacturers … to provide you with the best possible battery pack solution for your most demanding battery requirements.”
  • Integrated Battery Management (BMS) & Safety – A custom pack can include a tailored BMS that monitors voltage, current, temperature, cell balancing, and protects against over‑charge, over‑discharge, short circuit, and thermal runaway. That means better safety, longer cycle life, and fewer failures.
    Emerging Power mentions on its main site: “We offer design support for the total battery pack requiring a BMS, a PCB, Enclosure, Testing, Regulatory Support, Custom Programming” for even military applications.
  • Thermal Management & Environmental Robustness – High performance means higher demands on heat dissipation, durability, extreme temperature resistance, vibration, etc. When a pack is built custom, you can design the enclosure, connectors, cooling, or thermal shielding appropriately, delivering reliable performance even in harsh conditions.
  • Reduced Time to Market & Competitive Advantage Because custom battery packs align to your exact specifications, you avoid the “one size fits all” compromise. That means faster design cycles, fewer iterations, better fit with device architecture, and stronger differentiation in the marketplace.
  • Lifecycle Optimisation & Total Cost‑of‑Ownership – While custom packs may cost more upfront than generic ones, the overall lifetime value is higher: better cycle life, fewer replacements, fewer failures, and less maintenance downtime. For applications like medical devices, industrial sensors, drones, or military gear, that matters.

4. Use Cases: Where Custom Packs Make a Big Difference

Here are some real‑world scenarios where the value of custom battery packs is evident:

  • Medical devices: critical equipment cannot tolerate abrupt power dropouts or pack failures. Custom packs ensure reliability, compliance, and long life.
    For example, see our article on how lithium‑ion battery suppliers support the medical industry: Unlocking the Power: Lithium‑Ion Battery Suppliers and Custom Packs in the Medical Industry
  • Drones / UAVs: light‑weight, high‑power bursts and long flight time demand battery packs optimised for weight, discharge rate, cooling, and form‑factor.
  • IoT & smart sensors: devices often deployed remotely, in harsh environments, with long operating lifetimes and minimal maintenance. Custom packs can match shape, connector, and power profile to deployment.
  • Industrial instrumentation / rugged environments: in mining, oil & gas, outdoor sensor networks — battery packs must survive extreme temperatures, vibration, and deliver predictable performance.
  • Consumer / portable electronics: if your product differentiates by design (slim form, high runtime, fast recharge), then the battery pack becomes a key enabler.

5. Why Choose Emerging Power for Custom Battery Packs

Here’s why you should consider Emerging Power for your next battery‑pack design:

  • Depth of experience: more than 20 years designing and assembling custom battery packs for OEMs across markets, with ISO 9001:2015 and AS9100:2016 certification. 
  • Chemistry flexibility: the ability to work with multiple chemistries (Li‑ion, Li‑polymer, LiFePO₄, NiMH, etc.) and select the ideal one for your product. 
  • High‑quality supply chain: strong relationships with tier‑one cell manufacturers such as Panasonic, Samsung, LG, and Sony. 
  • Full design‑to‑production support: from cell selection, BMS, enclosure design, thermal & mechanical engineering, to regulatory testing and manufacturing. 
  • Market‑specific expertise: whether medical, industrial, military, IoT, or consumer, Emerging Power understands the unique regulatory and performance demands in each.
  • Focus on performance and safety: The company emphasises “Design for Safety – Built with Quality”. 

Best Practices When Specifying a Custom Battery Pack

When you engage with a partner like Emerging Power, consider these best practices to get the most from your custom battery pack:

  1. Start early in the device design process — involve the battery pack engineer while product architecture is still flexible. (Emerging’s site: “the earlier we are brought into the design process, the better.”)
  2. Define your load profile accurately — know your discharge/charge cycles, peak power bursts, standby, ambient conditions, and lifetime expectations.
  3. Choose the right chemistry and cell configuration — balance capacity vs power vs cost vs safety vs temperature.
  4. Specify environmental and mechanical constraints — size, form‑factor, connector type, vibration, shock, thermal cycling.
  5. Establish BMS and safety requirements — cell balancing, thermal cut‑off, over‑charge/over‑discharge protection, redundancy if needed.
  6. Plan for certification and regulatory compliance — medical, military, and consumer all have different rules.
  7. Evaluate lifecycle and serviceability — can the pack be replaced, monitored, serviced?
  8. Communicate with your battery partner — a good partner will guide you on trade‑offs, costs, manufacturability, and sourcing risks.

7. Conclusion

In summary: If you want your product to deliver higher performance, longer runtime, lighter weight, greater reliability, and faster time to market, then a custom battery pack designed specifically for your application is the logical choice. At Emerging Power, we bring the expertise, supply chain, engineering support, and manufacturing capability to make that happen.

By choosing a custom pack built by Emerging Power, you gain more than a battery; you gain a performance enabler. From the smallest sensor to the most demanding medical device, the right power solution makes the difference.

Improve your product performance with a custom battery pack
📞 Call us: (908) 546-5403
 📧 Email: sales@emergingpower.com

Or visit our product pages to learn more:

Safety & Regulatory Requirements for Battery Packs in Medical Devices

Introduction

Battery packs are the lifeblood of many modern medical devices, from portable infusion pumps to wearable monitors to emergency ventilators. But unlike consumer gadgets, battery packs in medical devices must meet far stricter safety, performance, and regulatory requirements. A single failure, such as thermal runaway, overcharge, or short circuit, can compromise patient safety, trigger recalls, or hinder regulatory approval.

This guide outlines the key safety and regulatory requirements for battery packs in medical devices, with a focus on U.S./FDA standards, global standards references, and practical tips for device makers and integrators. Use this as a blueprint to ensure compliance, accelerate approvals, and reduce risks.

 

Why Medical Device Batteries Need Extra Rigor (vs Consumer Batteries)

  • Patient safety is non-negotiable. Battery failure could lead to loss of life support, shocks, overheating, or internal burns.
  • Regulatory scrutiny. Medical devices fall under FDA, ISO, IEC, and industry standards. Battery modules are part of that system.
  • Lifecycle, traceability, and maintenance. Batteries degrade over time; cycles, usage history, and field behavior matter.
  • Interconnectivity and portability. Many medical battery packs charge while in use or power critical systems; these increase risk.

Because of this, battery packs in medical devices must satisfy both electrical/electronic safety and medical device regulatory norms.

 

Key Regulatory & Safety Standards for Medical Device Battery Packs

Below are the foundational standards and regulatory frameworks that should guide your system design and certification process:

1. FDA & U.S. Regulatory Framework

  • General Controls & Quality System Regulation (QSR, 21 CFR 820): Medical device manufacturers must adhere to design controls, risk management, change control, CAPA, and complaint handling. Battery packs are part of the device design.
  • 510(k) Premarket Notification / PMA: If your device is Class II (or higher) and uses a battery pack, your battery subsystem must be documented, tested, and sometimes benchmarked to predicate devices or recognized standards.
  • Consensus Standards Recognition: The FDA recognizes certain standards; for battery safety in medical devices, two key UL standards are now FDA‑recognized consensus standards: UL 2054 (battery pack safety) and UL 1642 (lithium battery cells). Conformance can streamline the review process.
  • Biocompatibility & Material Safety: Even though battery packs aren’t implanted themselves, device packaging and components near patient contact must meet biocompatibility evaluations per ISO 10993.

2. Electrical / Safety / Battery Standards (IEC, UL, UN)

  • IEC 60601 series: The general safety and essential performance standard for medical electrical equipment. A device using battery packs must meet the applicable parts (e.g., leakage current, insulation, protection) under IEC 60601.
  • IEC 62133: A standard for the safety of rechargeable cells and battery packs (especially Li-ion, NiMH) covers overcharge, short circuit, overdischarge, and mechanical abuse.
  • UL 2054 & UL 1642: As above, recognized by the FDA as consensus standards.
  • UN 38.3: For lithium-based batteries, the UN transportation test suite (altitude, vibration, thermal cycling, shock, short circuit, overcharge) is required. Many medical battery packs must pass UN 38.3 to be shipped legally.
  • Stress / Abuse Testing: Medical battery packs often must survive tests beyond nominal conditions — e.g., thermal extremes, shock, vibration, short circuits, charge cycling under load. 

Design & Risk Management Best Practices

Meeting standards is necessary, but good design ensures safety in real-world use. Here are the best practices:

  • Redundancy & fault tolerance: Use redundant cells or circuits so one failure doesn’t endanger the system.
  • Battery Management System (BMS): Incorporate over-voltage, under-voltage, overcurrent, temperature sensors, cell balancing, and fault detection.
  • Encapsulation, isolation, and shielding: Prevent leakage currents, isolate battery from patient‑touching surfaces.
  • Monitoring & telemetry: Log battery health, charge cycles, temperature, and alert if anomalies occur.
  • Field replaceability & traceability: Track battery lots, serial numbers, usage history, replacements.
  • Usability & human factors: Design battery insertion/removal so misuse is minimized (IEC 62366 usability engineering applies).
  • Lifecycle testing: Accelerated aging, deep cycling, calendar aging, and performance over time.
  • Labeling & instructions: Include warnings, safe charge/discharge ranges, removal instructions, and disposal guidance (in line with regulatory requirements).

Challenges & Pitfalls (and How to Avoid Them)

Challenge Risk Mitigation / Tip
Overreliance on battery manufacturer specs Real use conditions (temp, load) differ Conduct your own testing under worst-case loads
Non‑compliance with consensus standards Regulatory delays or rejections Use recognized standards (UL 2054, UL 1642) and document conformity
Battery aging & drift over time Device failure in the field Monitor battery health; design fail-safe discharge cutoffs
Improper charging during device operation Risk during use or charging BMS must manage charging safely; isolate when needed
Interference with medical device electronics Instability, noise, leakage Shielding, proper grounding, EMI/EMC testing
Lack of traceability Hard to manage recalls or servicing Use serial numbers, lot tracking, and usage logs

 

Conclusion 

Ensuring the safety & regulatory compliance for battery packs in medical devices is complex, but it’s non-negotiable. By aligning your design and testing strategy with FDA‑recognized standards (UL 2054, UL 1642), IEC 60601, IEC 62133, and UN 38.3, and embedding robust risk management, traceability, and usability, you dramatically reduce regulatory friction and safety risk.

At EmergingPower, we specialize in delivering medical-grade battery pack solutions that are engineered to meet or exceed regulatory requirements, helping device developers bring safer, compliant products to market faster.

Want help designing a regulatory‑ready battery subsystem, or reviewing your compliance plan? Contact us to discuss your specific project needs.

How to Choose a Custom Battery Pack Manufacturer: 10 Key Tips

Introduction

As the demand for smarter, safer, and more energy-efficient products continues to grow, so does the need for reliable and high-performance power solutions. Whether you are building medical equipment, industrial tools, electric vehicles, or consumer electronics, the right custom battery pack can make or break your product.

But how do you choose the right custom battery pack partner?

For OEMs, this decision is not just about sourcing a battery. It is about finding a technology partner who can support your vision from design to deployment. In this guide, we will walk you through ten essential criteria that every OEM should consider before selecting a custom battery pack manufacturer.

1. Engineering Expertise and Technical Capabilities

Your battery pack needs are unique, and a true partner should have the engineering skills to meet them. Look for a company that specializes in custom battery pack design and battery management systems. They should be able to support everything from cell selection and pack design to firmware development and system integration.

The ideal partner will have in-house engineers, proven design experience, and the ability to customize solutions based on your specific voltage, capacity, communication protocols, and space constraints.

2. Proven Experience with OEM Battery Pack Solutions

An experienced partner understands the complexity of OEM product development. They know how to collaborate with your internal teams, meet your timelines, and align with your production goals.

Ask potential partners about their past OEM projects. Have they worked in your industry before? Do they understand the regulatory and safety requirements for your application? Proven success in delivering OEM battery pack solutions is a key sign of a reliable partner.

3. Customization Capabilities

Every product is different, and off-the-shelf battery packs often do not meet the specific demands of your application. That is why customization is critical.

A strong partner should offer flexibility in battery chemistry, pack dimensions, protection circuits, connectors, and communication protocols. They should be able to design and build a battery pack that fits perfectly with your device, both mechanically and electronically.

4. Battery Management System Integration

Modern battery packs are more than just a collection of cells. They need smart battery management systems to monitor safety, performance, and longevity.

Your custom battery pack partner should be able to develop or integrate a BMS that includes features such as overvoltage protection, thermal management, state of charge monitoring, and fault detection. A well-designed BMS ensures reliability and reduces the risk of failure in the field.

5. Quality Control and Testing Processes

OEMs must ensure that their battery packs meet strict quality standards. Your partner should follow industry best practices for quality control, including incoming inspection, in-process testing, and final pack validation.

Look for a company that performs 100 percent testing on every battery pack and maintains detailed records for traceability. Ask about their certifications, such as ISO 9001 or IATF 16949, which indicate a strong quality management system.

6. Regulatory Compliance and Safety Certifications

Safety is a top priority for any battery-powered product. Your partner should be knowledgeable about regulatory requirements in your target markets and be able to help you meet compliance standards.

This includes certifications like UL, CE, IEC, UN 38.3 for transportation, and other safety and environmental standards. A partner with experience navigating these requirements can save you time and reduce the risk of compliance issues during launch.

7. Scalable Manufacturing Capabilities

As your business grows, your battery partner should be able to scale with you. Whether you need low-volume prototypes or high-volume production, the right partner will have the manufacturing infrastructure to meet your needs.

Ask about their production capacity, lead times, and ability to scale quickly. A flexible manufacturer can adapt to your changing demands and support you through every stage of your product lifecycle.

8. Transparent Communication and Project Management

Good communication is the foundation of any successful partnership. You need a battery pack partner who responds quickly, provides clear timelines, and keeps you informed throughout the design and production process.

Look for a partner who assigns a dedicated project manager and uses structured communication tools to ensure transparency and alignment. Regular updates and milestone tracking help keep your project on schedule.

9. Strong Supply Chain and Component Sourcing

A custom battery pack is only as reliable as the components inside it. Your partner should have strong relationships with top-tier cell manufacturers and component suppliers. This ensures consistent quality and availability.

Inquire about their sourcing strategy, preferred vendors, and how they handle supply chain disruptions. A resilient supply chain is critical for keeping your production on track.

10. Long-Term Support and Service

Your relationship with a battery pack partner should not end after delivery. Post-sale support is essential, especially when it comes to field performance, firmware updates, repairs, and replacements.

Choose a partner who offers long-term technical support, warranty services, and ongoing collaboration as your product evolves. The best battery pack manufacturers act as an extension of your team.

Final Thoughts

Choosing the right custom battery pack partner is one of the most important decisions you will make as an OEM. It affects your product’s safety, performance, reliability, and customer satisfaction. By evaluating potential partners using the ten criteria outlined above, you can minimize risk and set your project up for success.

At Emerging Power, we specialize in designing and manufacturing custom battery packs and smart battery management systems tailored to OEM requirements. Whether you are building medical devices, industrial equipment, or next-generation electronics, we are here to help you power your innovation with confidence.

Looking for a trusted custom battery pack partner? Contact Emerging Power today to start the conversation.

📞 Contact Us
 Website: https://emergingpower.com
 Phone: (201) 441-3590
 Email: sales@emergingpower.com

How 3D Printing Is Transforming Custom Battery Pack Manufacturing in the U.S.

Introduction

In today’s competitive energy landscape, battery manufacturers in the USA are under pressure to deliver safer, smaller, and more efficient energy solutions—faster than ever. One innovation leading this shift is 3D printing manufacturing, also known as additive manufacturing. From rapid prototyping to next-gen solid-state battery designs, 3D modeling and 3D printing are unlocking new frontiers for custom battery pack production.

In this blog, we’ll break down how 3D printing is shaping the future of Li-ion battery manufacturing, the top use cases, benefits, challenges, and what the road ahead looks like.

 

What Is 3D Printing in Battery Manufacturing?

3D printing allows manufacturers to build components layer by layer from a digital model, creating complex geometries that traditional processes can’t easily match. In battery production, this includes:

  • Printed casings and pack enclosures
  • Internal cooling structures for thermal regulation
  • Custom cell layouts and curved or embedded housings
  • Advanced solid-state components are printed directly

By integrating 3D modeling early in the design process, battery manufacturers gain a powerful edge in customization and performance.

 

Top Emerging Use Cases for 3D Printing in Battery Packs

1. Solid-State / All-Printed Battery Cells

Researchers are 3D-printing entire battery cells—including electrodes and electrolytes—for safer, high-density solid-state batteries.

 

2. Custom Conformal Designs

With 3D modeling, housings can be printed to match any device contour. Ideal for medical, wearable, and aerospace applications needing non-planar battery integration.

 

 3. Thermal Management Structures

Internal heat sinks, airflow channels, or porous lattices can be printed inside battery enclosures to control temperature, improving safety and lifespan.

 

4. Rapid Prototyping

3D printing accelerates R&D cycles. No need for molds or tooling—just print, test, and iterate. This agility gives Li-ion battery manufacturers a significant go-to-market advantage.

 

5. Integrated All-in-One Packs

Print casings, cooling, and connector features as one part—reducing assembly steps, weight, and complexity.

Why It Matters for U.S. Battery Manufacturers

Advantage Impact
Design Flexibility Custom geometries, shapes, and fit for specific devices
Performance Boost Shorter ion paths, optimized electrodes, better heat regulation
Safety Improvements Stronger enclosures, built-in cooling, fewer failure points
Cost & Waste Reduction Less material waste, no tooling, fewer production stages
Faster Product Development Rapid prototyping = faster innovation cycle and reduced time-to-market

Key Challenges to Consider

  • Material Compatibility: Not all battery materials (e.g., solid electrolytes) work well with current printing tech.
  • Throughput at Scale: 3D printing lags in speed for high-volume EV pack production.
  • Equipment Costs: High initial investment and expertise required.
  • Post-Processing: Printing may still require curing, assembly, and finishing steps.

What’s Next: The Future of Battery Manufacturing with 3D Printing

  • Fully Printed Batteries: Printing cells, enclosures, and connectors in one build
  • Hybrid Production Models: Mixing 3D printing with CNC and injection molding
  • New Printable Materials: Graphene, solid electrolytes, and nano-inks
  • Standardization & Compliance: Evolving UL, UN38.3, and IEC standards to include 3D-printed components

FAQ 

Q1: Can 3D printing fully replace traditional battery production?
 Not yet—but it’s rapidly replacing steps like prototyping, casing, and small-batch production.
Q2: Is 3D modeling hard to implement for battery parts?
 It requires CAD expertise and material science knowledge, but delivers huge returns in design precision.
Q3: Is it safe to use 3D-printed battery components?
 Yes, when using flame-retardant materials and following industry certifications like UL and UN38.3.

 

 

Ready to Integrate 3D Printing Into Your Battery Projects?

Emerging Power offers end-to-end custom battery pack development with in-house 3D printing capabilities. Whether you’re building a medical device, wearable, industrial sensor, or UAV — we provide prototyping, design, and smart integration solutions that reduce time and cost without compromising safety.

📞 Contact Us
 Website: https://emergingpower.com
 Phone: (201) 441-3590
 Email: sales@emergingpower.com

How to Choose the Best Lithium-Ion Battery Supplier in 2026

Introduction: Why Supplier Choice Matters in 2026

As the global demand for energy storage continues to surge, choosing the right lithium‑ion battery supplier in 2026 is no longer just about pricing; it’s about reliability, compliance, and long‑term scalability.

Whether you’re in EV manufacturing, solar storage, telecom, or industrial IoT, your success depends on working with lithium‑ion battery suppliers who can deliver consistent quality, technical support, and certified products.

In this guide, we’ll show you exactly how to evaluate and choose the best Li‑ion battery suppliers in 2026 and why Emerging Power is one of the leading names to trust.

What Makes a Great Lithium‑Ion Battery Supplier in 2026?

Choosing the right supplier requires more than reviewing specs. Here’s what truly matters:

1. ✅ Certifications & Compliance
Always choose a lithium‑ion battery supplier with global compliance:
• ISO 9001 – Quality management
• UN 38.3 – Safety for battery transportation
• RoHS / CE / UL – For international markets
• Custom certifications for EV, telecom, or energy storage applications

📎 View our certifications →

2. 🏭 Manufacturing Capabilities
Look for suppliers with scalable production facilities and a proven track record. This includes:
• In‑house cell design & BMS integration
• Flexible production volumes (prototypes to mass scale)
• Stringent quality control on every batch

🔗 Explore our Battery Manufacturing Process

3. 💡 Technical Support & Customization
Top li ion battery suppliers don’t just ship boxes — they support your engineering teams with:
• Custom battery pack solutions
• BMS integration guidance
• Thermal and mechanical design support
• Lifecycle optimization

4. 🌱 Sustainability & Long‑Term Value
Choose a supplier that’s thinking beyond the next shipment:
• Recyclable cell materials
• Compliance with environmental standards
• Long cycle life + product warranty
• Transparent sourcing of lithium and rare earths

5. 💰 Transparent Pricing & Lead Time
Pricing is important, but beware of hidden costs. Ask for:
• Cost per Wh or kWh
• Customization charges
• Shipping & duties
• Delivery lead times (especially for global supply chain disruptions)

Red Flags to Avoid When Evaluating Suppliers
Even in 2026, many buyers fall into avoidable traps. Watch out for:
• No certifications or unverifiable documents
• No technical support or limited communication
• Overpromising on specs or delivery
• Lack of traceability in raw materials
• Suspiciously low prices (often = low quality or safety risks)

Why Emerging Power Is One of the Best Lithium‑Ion Battery Suppliers in 2026
At Emerging Power, we’ve built a reputation as a trusted lithium‑ion battery supplier for industries across the globe.

✔ ISO‑certified facility in the USA
✔ Proven supply chain reliability
✔ Scalable production & full customization
✔ Fast lead times & dedicated support

Looking for reliable Li‑ion battery suppliers? Let’s talk → Contact Us

Trusted Lithium‑Ion Battery Supplier
Looking for a lithium‑ion battery supplier that delivers quality, compliance, and speed?

Emerging Power is here to power your innovation in 2026.

Call us: (201) 441‑3590
Email: sales@emergingpower.com

Request a Quote

Frequently Asked Questions (FAQs)

Q1. What certifications should I look for in a lithium‑ion battery supplier?
A: At minimum: ISO 9001, UN 38.3, and region‑specific certifications like UL, CE, and RoHS.

Q2. What’s the difference between a battery supplier and a manufacturer?
A: A supplier provides complete battery solutions and may partner with manufacturers. Some, like Emerging Power, are vertically integrated, handling both manufacturing and supply chain.

Q3. How do I know if a lithium‑ion battery supplier is reliable?
A: Look for verified client references, international certifications, transparent processes, and technical documentation.

Q4. Can Emerging Power customize battery packs for my application?
A: Yes! We offer custom solutions for medical, telecom, EV, energy storage, and industrial applications.

Q5. What’s the typical lead time for bulk orders?
A: Lead time depends on specs and quantity. Standard orders ship within 2‑6 weeks. Contact us for exact timelines.

Final Thoughts

In 2026, selecting the right lithium‑ion battery supplier can set your business up for success or failure. The best suppliers offer more than just batteries; they offer partnership, expertise, and peace of mind.

Choose wisely. Choose Emerging Power.

Why Drones Need Custom Battery Packs to Perform Well

Drones are reshaping industries from agriculture to defense, logistics to media production. But behind every high-performing drone is a powerful, reliable battery pack designed for its unique needs. Off-the-shelf batteries just don’t cut it anymore.

In this blog, we’ll explore why custom drone & UAV battery packs are essential for optimal drone performance, backed by real-time market data and industry insights.

The Drone Battery Market: A Skyrocketing Opportunity

The global drone battery market was valued at $8.13 billion in 2024 and is projected to soar to nearly $49 billion by 2033, growing at a robust 21.9% CAGR (Grand View Research, 2024).

In the U.S., demand for drone batteries is exploding, with growth from $1.86 billion in 2023 to over $11.6 billion by 2034 (Precedence Research, 2024).

Why this growth? Increasing drone applications in commercial and military sectors require batteries tailored for long flight times, safety, and power efficiency.

Why Off-the-Shelf Batteries Fall Short

Standard batteries, often mass-produced by generic battery manufacturers in the USA or overseas, face key limitations:

  • Weight Issues: Excess weight reduces flight duration and agility.
  • Power Delivery: Generic packs can’t meet the high bursts needed during critical maneuvers.
  • Thermal Management: Off-the-shelf batteries may overheat, posing a safety risk and reducing their lifespan.
  • Form Factor: Ill-fitting batteries cause integration issues affecting drone design and aerodynamics.

Benefits of Custom Drone & UAV Battery Packs

Custom battery packs engineered by specialists like Emerging Power provide tailored solutions for commercial and military UAVs:

1. Optimized Flight Performance

Designed for your drone’s unique power demands, these batteries maximize flight time and payload capacity.

2. Enhanced Safety Features

Built with advanced thermal and electrical safeguards to prevent overheating, short circuits, and failures.

3. Longer Operational Life

Custom packs withstand demanding use cycles, reducing downtime and replacement costs.

4. Seamless Integration

Sized and shaped to perfectly fit your drone’s architecture, improving reliability and aesthetics.

Emerging Power: Your OEM Battery Pack Partner

At Emerging Power, we specialize in custom drone & UAV battery packs crafted to exact specifications for both commercial and military drones. Our expertise ensures:

  • High-energy-density battery cells
  • Robust safety and protection circuits
  • Compliance with industry standards
  • Customizable solutions for unique UAV requirements

Discover how our commercial and military drone battery pack solutions elevate drone performance and reliability.

Final Thoughts

As drone technology advances, investing in custom drone batteries becomes non-negotiable. Don’t compromise performance and safety with generic battery packs. Partner with trusted manufacturers like Emerging Power to ensure your drones stay powered, efficient, and mission-ready.

Contact Emerging Power Today!

Ready to optimize your drone’s power system? Contact Emerging Power, the leading battery manufacturer in the USA, specializing in custom drone & UAV battery packs.

📞 Phone: (201) 441-3590
 📧 Email: sales@emergingpower.com