Introduction
When your product requires more than a single cell, a custom lithium polymer battery pack is the solution. Whether you need a multi-cell configuration for higher voltage, integrated BMS for smart communication, or a compact assembly for a wearable device, A&S Power delivers fully customized battery packs tailored to your OEM specifications.
As a dedicated custom lithium polymer battery manufacturer, we provide end-to-end pack assembly services – from cell selection and BMS design to final encapsulation and labeling. Our engineering team works closely with you to ensure your battery pack integrates seamlessly into your product, meets safety certifications, and performs reliably over thousands of cycles.
For a complete overview of our custom polymer battery capabilities, check out our full guide: Custom Lithium Polymer Battery – OEM/ODM Solutions for IoT, Wearables & Medical Devices .
What Is a Custom Lithium Polymer Battery Pack?
A lithium polymer battery pack is an assembly of one or more Li-Po cells connected in series, parallel, or series-parallel configurations to achieve the desired voltage and capacity. The pack typically includes:
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Protection Circuit Module (PCM): Overcharge, over-discharge, short-circuit, and overcurrent protection
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Battery Management System (BMS): Advanced monitoring, balancing, and communication (I²C, SMBus, CAN)
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Encapsulation: Heat-sealed pouches, plastic housings, or custom-molded enclosures
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Terminals: Wire leads, connectors (JST, Molex, Anderson), or solder pads
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Labeling: OEM branding with your logo and product information
Custom lithium polymer battery packs are used in medical devices, IoT sensors, portable electronics, drones, and industrial equipment where standard off-the-shelf batteries cannot meet the space, performance, or communication requirements.
Key Components of a Custom Battery Pack
1. Cell Selection
The foundation of every pack is the cell. We offer a wide range of lithium polymer pouch cells with varying capacities, dimensions, and discharge rates. Based on your product’s power requirements and physical constraints, we recommend the optimal cell for your application.
2. Protection Circuit Module (PCM)
Every pack includes a PCM that provides essential safety functions:
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Overcharge protection (prevents cell voltage exceeding safe limits)
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Over-discharge protection (prevents cell voltage dropping too low)
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Short-circuit protection (immediate disconnect in fault conditions)
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Overcurrent protection (limits excessive current draw)
3. Battery Management System (BMS)
For advanced applications, we integrate a BMS that offers:
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Cell balancing: Ensures all cells in a multi-cell pack maintain equal voltage
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State monitoring: Tracks State of Charge (SoC), State of Health (SoH), temperature, and current
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Communication: Supports I²C, SMBus, CAN bus, and HDQ protocols for smart device integration
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Fault diagnostics: Reports abnormal conditions to the host device
4. Encapsulation & Packaging
Depending on your product’s environment, we offer:
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Heat-sealed pouch wrapping: Lightweight and compact
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Plastic housing: Rigid protection for industrial applications
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Custom-molded enclosures: Full mechanical integration into your product chassis
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Conformal coating: Moisture and dust resistance
5. Termination Options
We support all standard and custom termination types:
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Wire leads with custom length and gauge
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JST, Molex, Hirose, and Anderson connectors
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Solder pads for direct PCB mounting
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Custom wiring harnesses
Why OEM Buyers Choose A&S Power for Custom Battery Packs
✅ Engineering Support from Concept to Production
Our in-house engineers provide design reviews, thermal modeling, and electrical simulation to ensure your pack performs as expected. We support you from initial specification through prototyping, testing, and mass production.
✅ Full Compliance Documentation
Every battery pack includes comprehensive compliance documentation:
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UN38.3 test summary for safe transport
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UL/CE/RoHS certificates for market access
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IEC62133 test reports
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Material Safety Data Sheets (MSDS)
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Batch-level traceability records
✅ Rigorous Quality Control
We test every pack before shipment. Our QC process includes:
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100% visual inspection
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Open-circuit voltage (OCV) and internal resistance (ACIR) testing
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Functionality and communication testing
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Insulation resistance and high-voltage testing
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Thermal cycling and aging tests (for sample batches)
✅ Flexible Volumes
From prototype quantities to high-volume production, we scale with your project. Our manufacturing facility supports both small-batch custom runs and mass production lines.
✅ Competitive Factory Direct Pricing
As a factory-direct custom lithium polymer battery manufacturer, we eliminate middlemen and pass the savings to you – without compromising on quality or support.
Applications for Custom Lithium Polymer Battery Packs
Our custom battery packs power products across multiple industries:
| Industry | Applications |
|---|---|
| Medical | Portable monitors, infusion pumps, surgical tools, patient tracking devices |
| IoT | Environmental sensors, asset trackers, smart home devices |
| Wearables | Smartwatches, fitness bands, smart clothing, hearing aids |
| Portable Electronics | TWS earbuds, Bluetooth speakers, wireless keyboards |
| Industrial | Handheld scanners, test equipment, robotics |
| Drones & UAVs | High-discharge packs for flight and FPV systems |
Quality Assurance Checklist for OEM Buyers
When evaluating a battery pack supplier, verify these five points:
| Check Point | Why It Matters |
|---|---|
| UN38.3 Certification | Mandatory for air and sea transport – without it, freight forwarders will reject your shipment |
| UL/CE/RoHS Compliance | Required for North American and European market access |
| ISO9001/ISO14001 | Ensures consistent quality management and environmental responsibility |
| Traceability | Batch-level documentation for every order – essential for audits and recalls |
| End-of-Life Handling Policy | Demonstrates the supplier’s commitment to regulatory compliance and sustainability |
A&S Power meets all five checkpoints and provides full documentation with every order.
Frequently Asked Questions (FAQ)
1. What is the MOQ for custom lithium polymer battery packs?
MOQ depends on the complexity of the pack. For standard single-cell packs, MOQ starts at 1,000 units. For complex multi-cell BMS-integrated packs, we can accommodate lower volumes for prototyping.
2. How long does the custom pack development process take?
Typical timeline: specification review (3-5 days) → engineering sample (2-3 weeks) → testing and validation (1-2 weeks) → mass production (4-6 weeks after sample approval).
3. Can you integrate a custom BMS with specific communication protocols?
Yes. We support I²C, SMBus, CAN bus, HDQ, and custom protocol development.
4. Do you provide design assistance for integrating the battery pack into my product?
Yes. Our engineering team offers mechanical and electrical integration support, including 3D CAD modeling and thermal analysis.
5. What certifications do you provide with each order?
We provide UN38.3 test summary, UL/CE/RoHS certificates (where applicable), MSDS, batch test reports, and traceability documentation.
Get a Quote for Your Custom Lithium Polymer Battery Pack
Ready to discuss your project? Contact A&S Power today.
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We provide full compliance documentation and technical support with every order – so you can focus on your product, not regulatory paperwork.
Dongguan A&S Power Technology Co., Limited.
Building 1, No. 2, Keji 9th Road, Songshan Lake, Dongguan, Guangdong, China
📞 +86 137 1383 1631 | ✉ info@enerbe.net