High-Reliability Custom Smart Battery Pack Manufacturing
With over four decades of engineering excellence, Cell-Con, Inc. is a premier U.S. manufacturer specializing in high-reliability custom smart battery pack assembly. We engineer portable power systems ranging from straightforward mechanical pack designs to highly sophisticated, multi-cell intelligent battery systems. Designed specifically for global Original Equipment Manufacturers (OEMs), our custom battery packs power critical applications in medical devices, military electronics, industrial automation, and robotics.
Our engineering team works closely with OEM product designers through every phase of development—from initial chemistry selection and circuit layout to custom enclosure prototyping, regulatory compliance testing, and full-scale automated production. Whether your application demands SMBus, CANbus, or I2C communication protocols, low or high capacity storage, Cell-Con delivers turnkey custom battery solutions engineered to perform in demanding operational environments.
Advanced Battery Management Systems (BMS) & Communication Protocols
Modern smart battery packs rely on intelligent management electronics to ensure system safety, maximize cycle life, and provide precise fuel gauging. Cell-Con incorporates custom Battery Management Systems tailored to exact OEM specifications, featuring high-accuracy state-of-charge tracking and multi-tier protection circuitry.
- SMBus v1.1 & SBS Compliant Fuel Gauging
- CANbus (CANopen / J1939) Industrial Interfaces
- I2C & HDQ Serial Communication
- Over-Charge & Over-Discharge Protection
- Multi-Cell Thermal Monitoring & Cell Balancing
- Custom Encryption & Anti-Counterfeiting Hardware
Supported Cell Chemistries & Engineering Specifications
Selecting the optimal battery chemistry is essential for balancing energy density, discharge rates, operating temperature range, and service life. Cell-Con maintains direct partnerships with Tier-1 cell manufacturers, ensuring consistent sourcing of top-grade Lithium-Ion, Lithium Iron Phosphate (LiFePO4), and Nickel-Metal Hydride (NiMH) cells.
| Chemistry | Nominal Cell Voltage | Energy Density | Cycle Life (80% DOD) | Primary OEM Applications |
|---|---|---|---|---|
| Lithium-Ion (Li-Ion) | 3.6V - 3.7V | High (150-250 Wh/kg) | 500 - 1,000 Cycles | Portable Medical Devices, Wearables, Handheld Electronics |
| LiFePO4 (LFP) | 3.2V | Medium (100-150 Wh/kg) | 2,000 - 4,000+ Cycles | Robotics, AGVs, Defense Systems, Marine Electronics |
| NiMH (Nickel Metal Hydride) | 1.2V | Moderate (60-120 Wh/kg) | 500 - 1,000 Cycles | Industrial Tools, Back-up Power, Legacy Equipment |
Turnkey Single-Source Partner: Battery Packs & Custom Chargers
System reliability depends on seamless interaction between the battery pack and its charger. Cell-Con acts as a single-source manufacturer for both custom battery assemblies and intelligent battery chargers. By designing the pack, BMS, charging algorithm, and mechanical enclosure in tandem, we eliminate integration risks, guarantee optimal charge efficiency, and accelerate time-to-market for OEM partners.
ISO 9001 Certified Quality Control & Global Compliance
Manufactured in our Bedford, Pennsylvania facility, every custom smart battery pack undergoes rigorous testing protocols to verify electrical parameters, BMS safety thresholds, and physical durability. We support complete international certification requirements, including UN 38.3 transport safety testing, UL 2054, IEC 62133, and CE compliance for global distribution.
Need a Custom Smart Battery Solution?
Consult with our senior battery design engineers to review your electrical, mechanical, and regulatory project requirements.
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