Custom battery development
Custom Lithium Battery Development — Built to Your Specs, from Prototype to Series.
When off-the-shelf batteries reach their limits, we develop your custom battery solution – from the first requirement to series production, all from one source.
Request a free initial assessmentWhen you should have a custom battery developed
No room for standard
Housing, shape and connectors must fit your device exactly – a battery built to spec instead of a compromise.
Special performance needed
High currents, long runtime or fast charging – the cell selection is calculated for your exact energy demand.
Harsh environment
Vibration, heat, cold or continuous duty – the battery is engineered for the real operating conditions.
How we develop your custom battery
A clear process with a dedicated contact – from the first requirement to the finished series.
1 — Requirement & consulting
Together we define space, performance, environment and quantity – the basis of every custom battery solution.
2 — Design & cell selection
Calculation of energy, current and service life, plus selection of the right cell chemistry (LiFePO4 for cycle life and safety, Li-NMC for high energy density).
3 — Prototype & test
We build a first battery to spec, test it under real conditions and match the BMS and charger.
4 — Series production
After your approval we manufacture reproducibly in series – including documentation and dangerous-goods certification (UN 38.3).
Battery built to spec
Precise housing and cell pack for devices that no standard battery fits.
High performance
Battery systems for high continuous and peak currents — cell selection and BMS parametrisation are calculated against the exact current demand.
Long service life
LiFePO4 cells and a robust BMS extend cycle life in continuous duty significantly compared to standard batteries.
Vehicles & machines
Custom batteries for special vehicles, intralogistics and mobile machinery.
Prototype & small series
From the first prototype to a reproducible small series – no catalogue minimum order.
Complete system
Battery, BMS and charger are engineered together and delivered as one coordinated complete system.
Case example
Custom battery for a mobile industrial device
An OEM manufacturer of mobile measurement devices needs a custom battery: compact enclosure, high discharge current for short measurements, operation at extreme temperatures and dangerous-goods certification for air transport. No off-the-shelf battery meets all four requirements simultaneously.
Hellpower defines cell chemistry (Li-NMC for high energy density), BMS protection parameters and enclosure dimensions together with the OEM. After a prototype and a test phase under real conditions, series production follows including UN 38.3 certification and full technical documentation for CE compliance.
The battery meets all requirements — installation space, performance, temperature range and transport regulations. The OEM receives a reproducible complete system (battery + charger) with a dedicated contact for repeat deliveries and further product development.
Why Hellpower Energy
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Dedicated contact
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Developed to spec
UN 38.3
Certified manufacturing
Frequently asked questions
- What does Hellpower mean by a 'battery built to spec'?
- A battery built to spec covers cell chemistry, BMS, enclosure, connectors and charger — all designed for your specific application. The basis is a technical requirements analysis capturing installation space, voltage, capacity, communication interface and operating conditions.
- Which cell chemistry is right for my application?
- LiFePO4 (lithium iron phosphate) is suitable for applications requiring long cycle life, high safety standards and continuous duty. Li-NMC offers higher gravimetric energy density and is preferred when weight or installation space is critical. The selection is made by calculation — not from a catalogue.
- What is UN 38.3 certification and when is it required?
- UN 38.3 is the dangerous-goods certification for lithium batteries in transport (air, rail, road, sea). It is mandatory for shipping lithium battery packs and is supplied by Hellpower as part of series production.
- How many steps does the development process involve?
- Four clearly defined steps: 1. Requirement & consulting, 2. Design & cell selection, 3. Prototype & test, 4. Series production. Customer approval is required at each step before the next begins.
- Can Hellpower supply a complete system of battery and charger?
- Yes — battery, BMS and charger are developed and supplied as a matched complete system. Charging parameters, communication interface and connectors are specified together.
Battery solutions for your industry
AGV & heavy-duty
Lithium batteries for AGV & heavy-duty
Custom battery systems for automated guided vehicles – moving up to 40 tonnes cable-free.
Intralogistics
Lithium batteries for intralogistics
Mobile power for warehouse operations and workstations – up to a week of runtime.
Battery knowledge
When a custom battery pays off
The criteria that decide whether your own battery solution is worth it.
Small series
Battery pack small series from a single unit
From prototype to series — with no minimum quantities, custom-made in Austria.
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Request your battery solution
Tell us about your application – we will tell you honestly whether and how a custom battery can be realised for you.
Request a free initial assessmentOr call us directly: +43 2265 20775 0