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Tag: custom battery packs

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

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How Do Lithium-Ion Rechargeable Batteries Contribute to the Growing Market for Smart Home Devices and IoT Solutions?

Lithium-ion rechargeable batteries have become the cornerstone of modern technology, particularly in the realm of smart home devices and IoT solutions. Lithium-ion rechargeable batteries provide the necessary power and efficiency that enable these devices to function seamlessly, ensuring reliability and long-lasting performance.

Understanding Lithium-Ion Battery Definition

Lithium-ion batteries are a type of rechargeable battery commonly used in consumer electronics and electric vehicles. They are favored for their high energy density, low self-discharge rate, and capability to deliver high current. These attributes make lithium-ion batteries ideal for devices that require long-lasting power and efficient performance.

Enhanced Energy Density for Smart Home Devices

Smart home devices, such as security cameras, smart locks, and thermostats, rely heavily on consistent and reliable power sources. Lithium-ion rechargeable batteries offer a high energy density, which means they can store more energy in a compact size compared to other battery chemistries. This is crucial for smart home devices that are often designed to be small and unobtrusive yet powerful.

Low Self-Discharge Rates Ensure Readiness

One of the significant advantages of lithium-ion rechargeable batteries is their low self-discharge rate. Unlike other rechargeable batteries that lose their charge over time even when not in use, lithium-ion batteries retain their charge for longer periods. This is particularly beneficial for smart home devices and IoT solutions that need to be always ready to operate without frequent recharging.

High Discharge Current for Performance

Smart home devices and IoT applications often require bursts of high power for short durations. Lithium-ion batteries are capable of delivering high discharge currents, ensuring that these devices can perform demanding tasks efficiently. For example, a smart lock may need a sudden high current to operate its locking mechanism, which lithium-ion rechargeable batteries can supply without compromising performance.

Custom Lithium-Ion Battery Packs for Specific Needs

Manufacturers of smart home devices and IoT solutions often require customized power solutions to meet specific design and performance criteria. Custom lithium-ion battery packs can be tailored to provide the optimal voltage, capacity, and form factor required by different devices. Emerging Power, for instance, offers custom battery solutions with a variety of chemistries such as lithium cobalt oxide, lithium manganese, and lithium iron phosphate, each catering to different performance and safety needs.

Long Cycle Life for Sustainability

The longevity of batteries is a critical factor in the sustainability of smart home devices. Lithium-ion batteries have a long cycle life, meaning they can be charged and discharged many times before their capacity significantly degrades. This long cycle life reduces the need for frequent battery replacements, thereby lowering the environmental impact and total cost of ownership for smart home devices.

Integration with Energy Management Systems

Smart home systems often include energy management components that optimize the use of power within the home. Lithium-ion rechargeable batteries can be integrated with these systems to store excess energy generated from renewable sources such as solar panels. This stored energy can then be used to power smart home devices, enhancing energy efficiency and reducing reliance on the grid.

Ending Notes

Lithium-ion rechargeable batteries play a vital role in powering the growing market for smart home devices and IoT solutions. Their high energy density, low self-discharge rates, ability to deliver high discharge currents, and long cycle life make them the preferred choice for these applications. Custom battery packs tailored to specific needs further enhance their utility, while safety and reliability ensure their suitability for a wide range of environments and uses. As smart home and IoT technologies continue to evolve, lithium-ion rechargeable batteries will remain at the forefront, driving innovation and efficiency in these domains.

Efficiency Redefined: The Impact of Custom Li-ion Battery Packs on Performance

Efficiency is key to success in every industry nowadays. Whether it’s powering essential devices or driving cutting-edge technology, Li-ion battery packs play a crucial role in meeting energy demands. However, off-the-shelf solutions may not always provide the efficiency and performance required for specialized applications. This is where custom battery packs come into play, offering tailored solutions to redefine efficiency and elevate performance.

Unlocking Enhanced Performance with Customization

Li-ion battery packs are renowned for their superior performance compared to traditional nickel or lead-based chemistries. With smaller size, reduced weight, and the highest energy density, Li-ion batteries are the preferred choice for applications requiring higher voltage and current requirements. However, not all applications have the same power demands or operating conditions. Custom Li-ion battery packs offer the flexibility to optimize performance based on specific requirements, whether it’s maximizing energy density, enhancing safety, or achieving high discharge rates.

Exploring Custom Lithium Battery Chemistries

Custom Li-ion battery packs are available in several chemistries, each offering unique advantages:

  • Lithium Cobalt Oxide: Provides the highest energy density, making it ideal for applications where maximizing energy storage capacity is critical.
  • Lithium Manganese: Offers greater safety with a lower energy density compared to lithium cobalt oxide, making it suitable for applications prioritizing safety.
  • Lithium Iron Phosphate: Provides high discharge rate capabilities and long cycle life, making it well-suited for applications requiring both power and durability.

The Impact on Performance

By harnessing the capabilities of custom Li-ion battery packs, industries can achieve unparalleled performance and efficiency. Whether it’s powering electric vehicles, portable electronics, or renewable energy systems, custom solutions ensure optimal performance tailored to specific needs. From extending runtimes and reducing downtime to improving reliability and safety, the impact of custom Li-ion battery packs on performance is undeniable.

At Emerging Power: Delivering Safety and Reliability

At Emerging Power, we prioritize safety and reliability in every custom Li-ion battery pack we design and manufacture. With a team of expert engineers specializing in electrical, mechanical, testing, and manufacturing, we ensure that every battery meets the highest standards of quality and performance. From concept to prototype, our project management team works closely with clients to understand their critical power specifications and deliver the best solutions for their applications.

Diverse Cell Agnosticism and Top Supplier Partnerships

In addition to our commitment to safety and reliability, Emerging Power stands out for its cell agnosticism and strategic partnerships with top battery cell suppliers. As an OEM and replacement battery manufacturer, we understand the importance of offering a wide range of battery chemistries and technologies to meet diverse application needs. Our partnerships with industry leaders such as Panasonic, Samsung, LG, and others ensure access to cutting-edge battery cells that power various portable electronic devices. By remaining cell agnostic, we provide our clients with the flexibility to choose the best battery solution for their specific requirements, further enhancing the efficiency and performance of custom Li-ion battery packs.

Wrapping Up

Custom Li-ion battery packs offer a transformative approach to powering today’s technology-driven world. By providing tailored solutions that optimize performance and efficiency, custom packs enable industries to meet evolving energy demands and overcome common power challenges. At Emerging Power, we are committed to delivering safe, reliable, and high-performance battery solutions that empower our clients to achieve their goals with confidence and success.