A custom lithium battery pack is built around your application, not the other way around. Whether it is an e-bike replacement battery, a robot power system, a drone pack or an industrial machine, the same six parameters decide the design: voltage, capacity, cell chemistry, dimensions, BMS and communication protocol. Here is how to define them — and what to send your manufacturer so the first quote is already close to the final solution.
1. Voltage: match the motor or system
Voltage determines compatibility with your motor controller or device input. Common pack voltages are 12V, 24V, 36V, 48V, 60V and 72V; higher-voltage systems (e.g. 96V for robots or industrial machines) are configured in series. Tell the manufacturer your nominal voltage and, ideally, the voltage window your device accepts (e.g. 40–54.6V for a 48V e-bike system).
2. Capacity and energy: your runtime requirement
Capacity (Ah) multiplied by nominal voltage gives energy (Wh), which is what actually decides runtime. State your target runtime (e.g. 60 km range or 4 hours of operation) and the average power draw of your device; the manufacturer converts that into Ah and cell configuration.
3. Cell chemistry: Li-ion (NMC) vs LiFePO4
Li-ion NMC cells offer higher energy density and are the default for e-bikes, power tools and robots. LiFePO4 offers longer cycle life and higher safety and is preferred for storage and heavy industrial use. See our comparison guide Li-ion vs LiFePO4: which chemistry fits your application.
4. Dimensions and connector: mechanical fit
Send the maximum available space (L×W×H in mm), the required connector type (XT60, Anderson, custom) and mounting requirements. If you are replacing an existing battery, a photo of the original pack plus its voltage/capacity marking is usually enough to start.
5. BMS: the battery’s safety brain
The Battery Management System protects cells from overcharge, over-discharge, over-current and temperature extremes, and it balances the cells. Specify your continuous and peak discharge current — a 150A-peak robot pack needs a very different BMS from a 15A power-tool pack. Also state whether you need low-temperature charging protection, balancing at the cell level, or a smart BMS with data output.
6. Communication protocol: RS485, CAN, Bluetooth, UART
If the device reads battery data, define the protocol: RS485 and CAN bus are the standard for robots and vehicles; Bluetooth is used for app monitoring; UART for embedded systems. Provide the data you need (SOC, cell voltages, temperature, cycles) and the manufacturer will map the BMS register table to your controller.
What to prepare before requesting a quote
- Application and environment (indoor/outdoor, temperature range, vibration)
- Nominal voltage and voltage window of the device
- Continuous and peak discharge current
- Target capacity or runtime
- Max dimensions, connector type and weight limit
- Required certifications (CE, UN 38.3, UL, IEC 62133) and target market
- Target annual quantity — this decides MOQ and tooling cost
With these details, XINYUEGE’s engineers design the pack, BMS and label together, and you receive a complete solution instead of a bare battery. Submit your project requirements or contact our team for a same-day assessment.
Frequently asked questions
What is the MOQ for custom lithium battery packs?
MOQ depends on the cell configuration and BMS. Standard 48V e-bike packs can start from small pilot quantities; fully custom packs with new tooling typically require a larger first order. Share your annual quantity and the manufacturer will propose the most economical plan.
How long does a custom battery take from design to delivery?
A typical cycle is: design and quotation in 3–5 working days, sample production 2–4 weeks, mass production 3–6 weeks depending on quantity and cell availability. UN 38.3 retesting, if required, adds time.
Can you copy an existing battery pack?
Yes. Send the original pack’s voltage, capacity, dimensions, connector and a photo; the manufacturer reverse-engineers the design and upgrades it with a fresh BMS and new cells.
What is the difference between RS485, CAN and Bluetooth BMS?
RS485 and CAN are wired protocols for real-time data exchange with controllers and chargers — the standard for robots and e-vehicles. Bluetooth is for app-based monitoring and configuration. Some BMS boards support two protocols at once.
Can the pack be designed for extreme temperatures?
Yes. Low-temperature charging protection, heated packs for cold climates and high-temperature-rated cells can all be configured, but they affect cost and cycle life — tell the manufacturer your operating range in advance.