From cell selection and battery pack architecture to BMS development, prototyping, testing and mass production, Yilai provides custom lithium battery solutions based on your voltage, capacity, current, dimensions, communication and certification requirements.
Yilai provides custom lithium battery pack design and manufacturing services for OEM equipment manufacturers, product developers and industrial system integrators. We support lithium-ion, lithium polymer, LiFePO4 and other rechargeable battery configurations, with customizable voltage, capacity, discharge current, dimensions, enclosure, connector, BMS and communication functions. Our engineering team can support projects from early-stage battery selection and feasibility review through prototype development, validation and volume production.
Every application has different requirements for runtime, output power, installation space, operating environment and regulatory compliance. Yilai develops custom lithium battery packs based on your electrical, mechanical and application-specific requirements.
From battery chemistry and cell configuration to BMS functions, enclosure design, connectors and certification support, each battery pack can be engineered to integrate with your equipment and production requirements.
| Customization Area | Available Customization Options |
| Battery Chemistry | Select from lithium-ion, lithium polymer and LiFePO4 battery technologies according to the required energy density, discharge performance, cycle life, operating temperature and safety requirements. Additional battery chemistries may be evaluated for specific projects. |
| Cell Format | Battery packs can be designed using cylindrical cells such as 18650 and 21700, pouch cells or prismatic cells. Cell format selection is based on available space, capacity, power output and mechanical structure. |
| Voltage | Nominal voltage and charging voltage can be customized through different series configurations to match the electrical input requirements of your equipment. |
| Capacity and Runtime | Battery capacity can be adjusted through cell selection and parallel configuration according to required runtime, available installation space, total pack weight and target energy output. |
| Discharge Current | Continuous discharge current, peak discharge current and discharge rate can be engineered around the starting current, operating load and peak power demand of the device. |
| Pack Configuration | Series and parallel configurations can be developed according to the required voltage, capacity, current and redundancy. The final configuration is confirmed after an engineering feasibility review. |
| BMS Functions | Available protection functions may include overcharge, over-discharge, overcurrent, short-circuit and temperature protection, as well as cell balancing, state-of-charge monitoring and fault detection. |
| Communication Protocols | Depending on the application, smart battery packs can support communication interfaces such as CAN, RS485, UART, SMBus or I²C for battery status monitoring and communication with the host system. |
| Mechanical Design | Available pack structures include heat-shrink wrapping, plastic housings, metal enclosures and application-specific custom housings. Mounting points, internal supports and component layout can also be customized. |
| Waterproofing and Environmental Protection | Sealing, potting, waterproof connectors, protective coatings and IP-rated enclosure designs can be evaluated for outdoor, marine, humid or dusty operating environments. |
| Connector and Cable Assembly | Connector type, wire gauge, cable length, terminal layout, fuse configuration and charging interface can be selected according to the equipment connection and installation requirements. |
| Temperature Performance | Battery packs can be designed for standard-temperature or low-temperature environments. Options such as low-temperature cells, temperature sensors and integrated heating functions may be considered where required. |
| Charger Compatibility | A matching charger can be selected or developed according to the battery chemistry, charging voltage, current, connector type and required charging time. |
| Certification Support | Project-based support may include UN38.3 transportation testing, IEC 62133, UL-related standards, CE, RoHS, REACH and other market-specific documentation. Certification requirements should be confirmed during the initial project evaluation. |
| Branding and Documentation | Custom labels, logos, packaging, user instructions, technical specifications, test reports and other project documentation can be prepared for OEM and private-label requirements. |
Not Sure Which Configuration Is Right for Your Application?
Provide your required voltage, capacity, continuous and peak current, maximum dimensions, operating temperature, communication requirements and estimated order quantity. Our engineering team will review the information and recommend a suitable custom battery pack design for further evaluation.
1.Highly Personalized Customization Solutions
1.1 Wide Compatibility with Various Devices
Whether it is a traditional device with a regular shape or a new device with a unique design, we can meet the battery customization requirements.
1.2 Precise Customization of Size and Shape
In response to the special appearance and internal space structure of customers' devices, we can accurately design the size and shape of lithium batteries.
Different applications require different balances of energy density, discharge performance, cycle life, size, weight and operating safety. Yilai supports multiple battery chemistries and cell formats, helping OEM customers select a suitable battery configuration based on equipment power demand, available installation space, operating environment and expected service life.
Our engineering team can assist with cell selection, series-parallel configuration, BMS integration, enclosure design, connector selection, prototyping and production validation.
Custom Lithium-Ion Battery Packs
ilai designs and manufactures custom lithium-ion battery packs using cylindrical cells such as 18650 and 21700. These cells provide a practical balance of energy density, discharge capability, mechanical stability and supply availability for a wide range of OEM applications.
The pack voltage, capacity and discharge current can be adjusted through different series and parallel configurations. Depending on the project, the battery pack can also incorporate a custom BMS, temperature sensors, communication functions, charging interfaces and protective enclosures.
Custom lithium-ion battery packs are suitable for applications requiring compact size, reliable runtime and flexible electrical configurations, including:
Robotics and automated equipment
Medical and beauty devices
Portable industrial instruments
Security and monitoring equipment
Communication devices
Power tools and handheld equipment
Smart home and IoT products
Custom Lithium Polymer Batteries
Yilai develops custom lithium polymer batteries for products with limited installation space, thin profiles or irregular internal structures. The pouch-cell construction allows greater flexibility in battery thickness, width, length, capacity and cable position than many conventional cylindrical-cell designs.
Custom LiPo batteries can be developed around the available internal space of the device. Options may include custom cell dimensions, protection circuits, connectors, wire lengths, thermistors, labels and packaging.
Lithium polymer batteries are commonly selected for lightweight and compact electronic products such as:
Wearable electronic devices
Smart sensors and IoT products
GPS and tracking equipment
Portable medical devices
Handheld terminals
Consumer electronic products
Compact monitoring and communication devices
The final cell size and capacity must be evaluated according to available space, charging requirements, discharge current and mechanical protection requirements.
Yilai provides custom LiFePO4 battery pack development for applications that prioritize cycle life, thermal stability, consistent output and long-term operating reliability.
LiFePO4 battery packs can be configured with different voltage, capacity and current specifications according to the equipment load and required operating time. Depending on the application, the pack may also include a BMS, battery status monitoring, communication interfaces, metal or plastic enclosures, waterproofing and matching charging solutions.
Custom LiFePO4 battery packs are suitable for industrial and high-capacity projects such as:
Industrial machinery and control systems
Automated guided vehicles and mobile robots
Energy storage equipment
Marine and outdoor equipment
Backup power systems
Electric mobility equipment
Solar-powered systems
High-capacity portable equipment
For projects involving high current, low-temperature operation or long-duration cycling, Yilai can evaluate the cell specification, thermal design, pack structure and protection strategy during the engineering review.
Smart Battery Packs with BMS and Communication
Yilai develops smart battery packs that combine rechargeable cells with battery management, protection and communication functions. These battery packs are designed for equipment that requires more than a basic power source and needs real-time access to battery operating information.
Depending on project requirements, the smart battery system may include:
Overcharge and over-discharge protection
Overcurrent and short-circuit protection
Cell voltage and temperature monitoring
Cell balancing
State-of-charge monitoring
Fuel-gauge functionality
Charging and discharging status monitoring
Fault detection and alarm functions
Cycle-count and usage-data recording
Communication with the host device
Available communication options may include CAN, RS485, UART, SMBus or I²C, subject to project feasibility and the equipment control system.
Smart battery packs are commonly used in robotics, medical equipment, industrial devices, marine systems, automated equipment and other applications that require battery status monitoring, system communication or preventive maintenance.
Yilai evaluates custom sodium-ion battery solutions for selected projects that require an alternative rechargeable battery chemistry. The suitability of sodium-ion technology depends on the required voltage, energy density, operating temperature, discharge performance, cycle life, installation space and commercial availability of suitable cells.
Because sodium-ion battery technology and cell specifications continue to vary between suppliers, every project requires an individual feasibility assessment before pack configuration, BMS selection, enclosure development and production planning can begin.
Potential applications may include selected energy storage, backup power and industrial equipment projects where the characteristics of sodium-ion chemistry match the operating requirements.
Which Battery Chemistry Is Right for Your Project?
The most suitable battery chemistry depends on more than voltage and capacity. Our engineers will also evaluate discharge current, runtime, available dimensions, operating temperature, expected cycle life, charging method, communication requirements, certification needs and target production quantity.
Submit your application requirements, equipment specifications or existing battery drawings, and Yilai will help evaluate an appropriate cell format, battery chemistry and pack configuration.
2.1 High-Performance Battery Materials and Technologies
We use high-quality electrode materials, separators, and electrolytes in lithium battery customization. These high-quality materials, combined with advanced manufacturing processes, endow our lithium batteries with characteristics such as high energy density and high voltage stability.
2.2 Strict Quality Inspection and Safety Standards
As a reliable custom battery manufacturer, Yilai Power ensures that each lithium battery undergoes multiple strict quality inspection procedures. From the inspection of raw materials to the performance testing of finished batteries, we follow the highest international standards.
Developing a reliable custom battery pack requires more than selecting cells and assembling components. Yilai follows a structured development process covering requirement analysis, engineering design, prototyping, validation and mass production.
At each stage, customers receive a clear technical or commercial deliverable, making it easier to review the project, provide feedback and approve the design before moving to the next phase.
1. Requirement Review
The project begins with a detailed review of your application and battery requirements. Our engineering team evaluates the electrical, mechanical, environmental and regulatory conditions that may affect the battery pack design.
Information reviewed may include:
Application and equipment type
Nominal and charging voltage
Required capacity and runtime
Continuous and peak discharge current
Maximum dimensions and weight
Operating and storage temperature
Charging method and charging time
BMS and communication requirements
Connector and cable specifications
Waterproofing or enclosure requirements
Target market and certification requirements
Prototype quantity and estimated annual demand
If an existing battery, specification sheet, drawing or equipment sample is available, it can also be reviewed during this stage.
Customer Deliverable:
A summarized battery requirement document confirming the main technical specifications, application conditions and project objectives.
2. Feasibility Assessment and Initial Concept
Based on the confirmed requirements, Yilai evaluates whether the proposed battery pack can be developed within the available size, performance, safety and budget constraints.
The feasibility review may cover:
Suitable battery chemistry
Cell format and cell model selection
Series and parallel configuration
Expected voltage and capacity
Continuous and peak current capability
Estimated runtime
BMS protection requirements
Communication protocol requirements
Charger compatibility
Internal layout and enclosure concept
Thermal management requirements
Certification feasibility
Cell and component availability
Where multiple configurations are possible, our engineers may compare different concepts based on energy density, cycle life, weight, cost, lead time and production feasibility.
Customer Deliverable:
An initial battery pack concept showing the proposed chemistry, cell configuration, electrical architecture, BMS approach and mechanical design direction.
3. Quotation and Detailed Design
After the initial concept is accepted, the project moves into quotation and detailed engineering design. During this stage, the battery pack specifications are refined and the major components are confirmed.
The design work may include:
Cell and component selection
Battery pack series-parallel structure
BMS hardware and protection settings
Communication interface definition
Connector and cable configuration
Fuse and temperature sensor selection
Enclosure and mounting design
Internal component layout
Label and packaging requirements
Charger selection
Bill of materials preparation
Preliminary production process planning
The quotation is prepared according to the confirmed technical configuration, prototype quantity, tooling requirements, testing scope and expected production volume.
Customer feedback on the quotation, specification or structural design is collected and incorporated before prototype production begins.
Customer Deliverable:
Formal quotation
Technical specification
Preliminary drawing or structural concept
Confirmed interface and connector information
Prototype schedule
Agreed project scope
4. Prototype Development
Once the design and quotation are approved, Yilai produces prototype battery packs for technical evaluation.
Prototype development may involve:
Cell sorting and matching
BMS assembly and programming
Pack welding and electrical connection
Cable and connector assembly
Enclosure manufacturing or modification
Insulation and protective material installation
Label preparation
Initial charging and discharging
Hardware and communication debugging
Basic protection-function verification
For smart battery projects, BMS parameters, fuel-gauge functions and communication data may be adjusted according to the host equipment and operating logic.
Prototype lead time depends on cell availability, BMS complexity, enclosure tooling, communication development and required testing.
Customer Deliverable:
Functional prototype battery pack
Prototype technical specification
Initial inspection or test results
Charger or supporting accessories, where included
Instructions for sample evaluation
5. Validation, Feedback and Final Approval
The prototype is tested to confirm that it meets the agreed electrical, mechanical and application requirements. Testing is determined by the battery design, application environment and certification needs.
Validation may include:
Capacity and runtime testing
Charge and discharge testing
Continuous and peak current testing
Internal resistance testing
BMS protection-function testing
Temperature monitoring
Communication and data verification
Cycle-life evaluation
Aging testing
Drop and vibration testing
High- and low-temperature testing
Waterproof or enclosure testing
Charger compatibility testing
Installation and equipment integration testing
The customer can also test the sample in the actual device or operating environment. Any confirmed feedback is reviewed by the engineering team and incorporated into the design where technically feasible.
If changes affect the battery structure, BMS, cell configuration, tooling, testing scope or certification plan, the specification and quotation will be updated before final approval.
Customer Deliverable:
Test or validation report
Updated technical specification
Revised sample, when required
Final approved battery design
Approved reference sample for mass production
6. Mass Production, Quality Control and Delivery
After the prototype and final specification are approved, the project moves into production preparation and volume manufacturing.
Before production begins, Yilai confirms:
Approved bill of materials
Cell and component sourcing
Production work instructions
Inspection standards
BMS settings and software version
Approved drawings and specifications
Label and packaging requirements
Traceability information
Production and delivery schedule
During manufacturing, quality-control procedures may include incoming material inspection, cell sorting, welding inspection, BMS testing, charge-discharge testing, aging, appearance inspection and final functional verification.
Completed battery packs are packed according to the agreed shipping and transportation requirements. Supporting documentation may include inspection records, batch information, specifications, test reports and transport documents, depending on the project.
After delivery, Yilai can assist with installation questions, technical feedback, product troubleshooting and future design updates. Feedback from field use may also be reviewed for later production batches.
Customer Deliverable:
Mass-production battery packs
Production inspection and quality-control records
Batch and traceability information
Final specifications and supporting documents
Packaging and shipping documentation
After-sales technical support
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