UK Battery Specialists

Custom Battery Pack Design & Manufacturing

From concept to production, our expert engineers design bespoke battery solutions tailored to your exact power requirements, budget, and application specifications.

30+ Years
Industry Experience
1000+
Designs Delivered
100% UK
Designed in the UK
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No obligation. Response within 24hrs · UK-based team
Expert Design Services

Battery Solutions Engineered for Your Application

AceOn has many years experience in battery pack design according to your power requirements, budget and time-frame. It's important to design the correct battery solution to maximise the potential of your application.

Our team of mechanical and electronics engineers deliver customised battery pack designs with the most suitable chemistry and configuration — no project is too small, too large, or too complicated.

Every custom pack is designed in the UK. Our design team can work with you throughout the whole process — from prototype right through to small or large-scale production.

30+
Years Building Custom Packs
  • Defence & Military
  • Medical & Healthcare
  • Oil, Gas & Marine
  • Rail & Automotive
  • Aerospace & IoT
Our Approach

Battery Pack Design Process

From initial consultation to production, we guide you through every step of the custom design journey.

01
Initial Consultation
Discuss your application, power needs, budget and timeline with our specialists.
02
Technical Design
Engineers develop detailed specifications, selecting optimal chemistry and safety systems.
03
Prototype Development
Build and test prototype units to validate design performance against your requirements.
04
Testing & Certification
Rigorous testing to UN38.3, IEC 62133, and industry-specific standards.
05
Scale Production
From small batches to large-scale manufacturing — consistent quality at any volume.
Design Capabilities

What We Deliver

Full-service engineering built around your specification.

Custom Configurations
Tailored voltage, capacity and form factor designs to fit your exact application and physical constraints.
Chemistry Selection
Expert guidance on Li-ion, LiFePO4, NiMH, NiCd, and primary lithium chemistries to optimise performance.
BMS Integration
Advanced Battery Management Systems with cell balancing, protection circuits, and smart monitoring.
Safety Engineering
Built-in protection against overcharge, over-discharge, short circuit, and thermal events.
Communication Protocols
SMBus, I²C, CAN bus, RS485 and other protocols for seamless system communication.
Enclosure Design
Custom housings with appropriate IP ratings, thermal management, and connector solutions.
Industry Expertise

A Few of the Sectors We Serve

From regulated safety-critical applications to high-volume commercial deployments — here are just some of the sectors we design custom battery packs for.

Medical & Healthcare
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Defence & Military
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Oil & Gas
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Marine & Subsea
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Rail & Transport
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Automotive & EV
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Aerospace & Aviation
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IoT & Connected Devices
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…and many more sectors served
Aerospace, industrial & manufacturing, renewables, emergency services, consumer electronics, robotics, agriculture — if you need a custom battery pack, we've likely designed for a project like yours.
Talk to us
Why AceOn

The AceOn Advantage

30+ Years Experience
Decades of expertise in battery technology, design innovation, and manufacturing excellence.
100% UK Designed
All design work takes place in our UK facilities in Telford, Shropshire.
Scalable Production
From single prototypes to high-volume production — we have the capacity to grow with you.
End-to-End Support
Our team works alongside you from concept through production and ongoing technical support.
Common Questions

Battery Pack Design FAQ

What information do you need to start a custom battery pack project?
To begin, we'll need details about your application's power requirements (voltage, capacity, discharge rates), physical constraints (size, weight, form factor), operating environment (temperature range, humidity, vibration), required certifications, and your projected volumes and budget. Our team will guide you through the specification process during the initial consultation.
How long does the custom battery design process take?
Typical design timelines range from 4–12 weeks depending on complexity. Simple configurations may reach prototype stage in 4–6 weeks, while more complex designs requiring custom BMS development or specific certifications may take longer. We'll provide a detailed timeline during project scoping and keep you updated throughout.
What battery chemistries do you work with?
We design with all major chemistries — Lithium-ion (Li-ion), Lithium Iron Phosphate (LiFePO4), Nickel Metal Hydride (NiMH), Nickel Cadmium (NiCd), and various primary lithium cells. Our engineers will recommend the optimal chemistry based on your application, balancing energy density, cycle life, safety, and cost.
What is the minimum order quantity for custom battery packs?
We're flexible on order quantities — from single prototypes through to high-volume production runs. No project is too small or too large. Many projects start with small quantities for evaluation before scaling up, and we're happy to support this approach.
Can you help with certification and compliance?
Yes. We design battery packs to meet relevant standards including UN38.3 for transport, IEC 62133 for safety, and industry-specific requirements for medical, defence, and other regulated sectors. We can guide you through the certification process and ensure your battery pack meets all necessary compliance requirements.
What is the Express Lane 7-day turnaround?
For qualifying repeat customers and simpler configurations, our Express Lane programme can deliver custom packs within 7 days from order confirmation. Ask about eligibility during your consultation — we'll let you know upfront whether your project fits.
Ready to Get Started?

Speak With Our Engineering Team

Discuss your requirements and discover how AceOn can deliver the perfect battery solution for your application. No obligation — just expert advice.

Book Your Free Consultation Call +44 (0)1952 293388