Custom Battery Pack Assembly
UK Assembled
Not only do we buy many off-the-shelf packs in all configurations, we also assemble bespoke battery packs to any configuration. This is done in our purpose-built assembly plant, with skilled assemblers and state-of-the-art equipment, providing our customers with quality workmanship and fast turnaround.
Battery Experts
We have been assembling battery packs for over 20 years and we’ve been selling batteries for even longer than that! Serving a whole host of industries and applications regardless of how niche it is, if you have a battery-related problem, we can solve it.
Battery Pack Design
At BBL, we produce battery packs tailored specifically to our customer’s requirements. Have you ever been asked for a battery for a pool table ball dispenser or a battery for portable sheep shears? We have and we can supply for pretty much any application no matter how specialist.
Why choose a custom battery pack rather than an off-the-shelf solution?
Our experienced battery experts explain why you might need a custom battery pack instead of a ready-made one.
You have unique specifications: Custom battery packs can be made for your device if you can’t find them in a regular store. Designers and manufacturers can create these packs to match your device’s specific voltage, capacity, or size needs.
You want improved performance: Custom battery packs can enhance performance, extend lifespan, and improve efficiency for specific uses. We tailor our bespoke battery packs to meet your needs, ensuring high-quality and reliable power solutions.
You want to save money: Custom battery packs can reduce overall costs in some cases. To save time and materials, we can use fewer, larger cells or customise the pack for a specific purpose.
You have specific safety requirements: If your device needs special safety features, a custom battery pack can be made with protective circuitry to meet those requirements. Our battery specialists ensure that each pack meets stringent safety standards.
You have limited space: We can create a custom pack to fit in small spaces and still provide sufficient power for the device. This is useful when there isn’t much room available for a battery. Custom packs are designed specifically to meet the power needs of the device while fitting within the limited space constraints. By creating a custom pack, the device can still function effectively despite the space limitations. Our design assembly process ensures a perfect fit for your application.
You want to extend the life of a product you’ve already purchased: Some great products, such as wheelchair power devices and battery-powered wave riders, come with their own OE battery packs. The engineers designed these battery packs to extend the product’s life. They are specifically made for these products. The OE battery packs are essential for the proper functioning of the devices.
When these batteries fail or arrive damaged, we can help. We can create a new pack for you in the UK. We will send it directly to your door. All we need is a sample and some information from you.
Our Custom Battery Pack Assembly Process
The custom battery pack assembly process at our dedicated battery pack manufacturing facility typically involves several steps.
Design
This involves determining the requirements for the battery pack, including voltage, capacity, size, shape, and any other specific needs. The design will typically include selecting the appropriate cells and determining the configuration and connection method.
Cell selection
Choosing the right cells is critical to ensuring that the battery pack meets the desired specifications. Factors to consider include voltage, capacity, discharge rate, and cost.
Configuration
This involves arranging the cells to meet the desired specifications. Different configurations, such as series or parallel, can be used to achieve the desired voltage and capacity.
Connection
Once the cells are arranged in the desired configuration, they need to be connected. This can be done using various methods, such as welding, soldering, or using connectors.
Testing and Quality Assurance
The assembled battery pack is then examined to ensure that it meets performance specifications and safety standards. This may include testing for capacity, voltage, and temperature performance, as well as verifying that the protection circuitry is functioning properly.
Our Expertise
- Designing and Manufacturing: We specialise in designing and manufacturing custom-built battery packs. Our battery technology expertise ensures that each pack is tailored to your specific needs.
- Battery Pack Manufacturing: Our manufacturing facility is equipped to handle all aspects of battery pack manufacturing, from design assembly to final production.
- Custom Battery Pack Design: We offer bespoke battery pack design services to create high-quality, custom power solutions that meet your exact specifications.
- Battery Pack Assembly: Our assembly process ensures that each battery pack is built to the highest standards, using the best materials and latest technology.
- Lithium Ion and Li-ion: We specialise in lithium-ion (Li-ion) technology, providing powerful, reliable, and efficient custom battery packs for a wide range of applications.
Whether you need a custom-built battery pack for unique specifications, improved performance, cost savings, specific safety requirements, limited space, or extending the life of a product, our team is here to help. Contact us to discuss your bespoke battery needs and discover how we can provide the perfect custom power solution for you.