Shenzhen Shangguo Technology Co., Ltd. is a leading high-tech enterprise specializing in the research, development, and manufacturing of high-quality replacement batteries for laptops,cameras, medical, industrial, specialty equipment, robot, outdoor energy, and other electronic devices!
Custom Battery Pack Size & Shape: How to Design a Battery for Limited Space
Learn how to design a custom battery pack for tight spaces, irregular battery compartments and demanding device requirements.
For many electronic devices, the battery cannot simply be selected from a standard size. Portable medical equipment, industrial instruments, smart devices, handheld tools and other compact products often have limited internal space.
A custom battery pack can be designed around the available space instead of forcing the device to accommodate a standard battery. Voltage, capacity, dimensions, shape, connector, wire length and protection functions can all be considered during battery design.
The first step in designing a custom battery is understanding the actual space available inside the device. Battery dimensions should be considered together with surrounding components, wiring and the battery compartment.
Important dimensions normally include length, width, height and available clearance around the battery.
Available horizontal space
Available side clearance
Maximum battery thickness
Battery cells can be arranged in different configurations to make better use of the available internal space. The best shape depends on the device structure and the required voltage and capacity.
Useful for thin portable electronics and compact equipment.
Suitable when cylindrical cells provide the required performance and layout.
Designed around non-standard battery compartments and internal structures.
Cells can be arranged to achieve the required voltage and capacity within available space.
A smaller battery does not automatically provide the required performance. Battery design needs to balance physical dimensions with voltage, capacity, discharge requirements and the device's operating time.
A battery may have the correct voltage and capacity but still fail to fit the device because of the connector position, wire length or pin configuration.
For a custom battery pack, the connector and wiring can be designed according to the device interface and internal assembly requirements.
Select the appropriate connector for the device interface.
Customize cable length according to internal routing.
Support different contact and pin requirements.
Consider where the connector exits the battery pack.
For rechargeable lithium battery packs, the protection system should be considered during the early design stage rather than added after the battery shape is finalized.
When the available space is limited, a prototype is an important part of custom battery development. The prototype can be checked against the actual device before moving to mass production.
Custom battery dimensions and shapes are especially useful for equipment where internal space is limited or the battery compartment has a non-standard design.
Portable medical and diagnostic equipment
Handheld instruments and inspection equipment
Compact electronics and smart home devices
Portable electronics and rechargeable devices
Portable outdoor and recreational equipment
Battery-powered handheld tools and equipment
Shangguo Technology provides custom battery pack design and OEM/ODM manufacturing for applications with limited internal space. We can develop battery packs according to your required voltage, capacity, dimensions, shape, connector, wire and packaging.
Shangguo Technology — Custom Battery Pack Design & Manufacturing
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