Bespoke Battery Pack Design & Manufacturing
Bespoke Solutions
When a bespoke battery pack makes sense
Custom battery packs are the right choice when standard modules cannot meet a critical requirement – whether that is voltage, current, footprint, integration constraints or lifetime in a harsh environment.
ZettaJoule works with OEMs, integrators and specialist builders who need engineered packs with tightly defined performance.
We support projects from early concept through to small-batch manufacturing, documentation, and integration support for your wider system.
Industries we support
- Low-volume mobility and EV platforms
- Industrial and OEM equipment
- Telecoms and critical infrastructure
- Off-grid, UPS and backup systems
- Specialty R&D and prototyping
Ready to scope a design?
From concept to validated pack
Our process is structured so that requirements, safety and manufacturability are considered at every stage:
- Requirements analysis – Electrical targets (voltage, current, energy), duty cycle, environment, lifetime, certification needs and budget.
- Cell selection – Chemistry, format and supplier evaluation based on performance data, cycle life and availability.
- Electrical architecture – Series/parallel configuration, current paths, protections, fusing strategy and isolation concept.
- Mechanical design – Enclosure, mounting, cooling, ingress protection and serviceability, modelled in 3D CAD.
- BMS integration – Selection and configuration of BMS, current sensing, contactors, DC/DC and communication interfaces.
- Prototyping and validation – Prototype build, functional tests and performance measurements against your specification.
- Industrialisation support – Build documentation, test plans, and support pilot production.
Typical protections and standards
- Cell- and pack-level voltage, current and temperature limits
- Redundant measurement and plausibility checks
- Contactors, pre-charge and discharge path protection
- Primary and secondary fusing strategies
- Insulation and isolation monitoring concepts
- Stress Testing
Safety-first by design
Bespoke packs often operate in environments where failure is not acceptable. Our design work starts from a safety concept that defines isolation, fault detection and controlled failure modes.
We prioritise, robust contactor and fuse strategies, conservative current derating and clear creepage/clearance design. Packs are engineered so that protections act predictably under abuse conditions, and test plans are built around your risk profile and target standards.
Where needed, we support you with the technical documentation.
We prioritise, robust contactor and fuse strategies, conservative current derating and clear creepage/clearance design. Packs are engineered so that protections act predictably under abuse conditions, and test plans are built around your risk profile and target standards.
Where needed, we support you with the technical documentation.
How this checklist is used
You do not need final answers for every topic before speaking to us, but the more detail you can provide, the faster we can converge on a suitable architecture and budgetary estimate.
Once we receive your enquiry, we review the information, clarify any gaps and propose a high-level design approach. From there, we can move into detailed engineering, prototyping and validation according to your project priorities.
Once we receive your enquiry, we review the information, clarify any gaps and propose a high-level design approach. From there, we can move into detailed engineering, prototyping and validation according to your project priorities.
Information to prepare
| Topic | What we need from you |
|---|---|
| Electrical targets | Nominal and maximum voltage, continuous and peak current, required energy (kWh) or runtime. |
| Duty cycle | Typical load profile, charge/discharge rates, daily usage, expected lifetime and cycle count. |
| Mechanical constraints | Maximum envelope (L × W × H), mounting options, weight limits, preferred connectors. |
| Environment | Ambient temperature range, vibration/shock, ingress protection needs, indoor/outdoor use. |
| Interfaces | Required communication buses (for example CAN, RS-485, Ethernet), I/O, alarms and integration with EMS/PLC. |
| Standards and approvals | Any transport, safety or application standards that the final product should support. |
| Project context | Intended application, volumes (prototype, pilot, production) and timeline constraints. |
