Custom Nickel Metal Hydride (NiMH) Battery Pack Design
As modern portable electronic equipment and commercial devices demand higher power density, compact footprints, and elevated safety standards, global OEMs require customized battery systems engineered for peak performance. Nickel Metal Hydride (NiMH) battery technology remains an exceptionally reliable, high-density, and cost-effective power source utilizing a nickel hydroxide positive electrode and a hydrogen-absorbing alloy negative electrode.
With over 40 years of battery manufacturing experience since 1983, Cell-Con, Inc. specializes in custom NiMH battery pack assemblies built to precise electrical, thermal, and mechanical OEM specifications. Operating from our ISO 9001 certified assembly facility in Pennsylvania, USA, our engineering team ensures absolute quality control, regulatory compliance, and seamless integration for global procurement partners.
Technical Specifications & Cell Configurations
NiMH cells feature a nominal voltage rating of 1.2V per cell, operating effectively within a usable discharge range of 1.0V to 1.45V per cell. By configuring cylindrical cells in custom series and parallel arrangements, Cell-Con designs battery packs delivering custom voltages, capacities, and form factors to meet specific application requirements.
| Specification Parameter | Standard Technical Range |
|---|---|
| Nominal Cell Voltage | 1.2V (Usable Range: 1.0V – 1.45V per cell) |
| Capacity Range | 100mAh to 10Ah+ (Custom Parallel Strings) |
| Discharge / Charge Capability | Up to 1C continuous (Rapid 1-hour fast charge option) |
| Cell Sizes Available | AAA, AA, A, 4/5A, Sub-C, C, D, and specialized prismatic cells |
| Operating Temperature | -20°C to +60°C (Extended temperature cells available) |
| Safety & Protection | Thermostats, Thermal Fuses, NTC Thermistors, Custom Polyswitches |
Product Gallery & Custom Assemblies
Our custom NiMH battery packs are built using top-tier brand cells (such as Panasonic, FDK, and Saft), heavy-duty nickel tabs, ultrasonic spot welding, and durable shrink sleeving or molded plastic enclosures.
Key Applications & Global OEM Markets Served
NiMH custom battery packs offer an ideal balance between high energy density, transport safety, and cost efficiency. Key global industries benefiting from custom NiMH solutions include:
- Medical Devices: Backup power for ventilators, diagnostic equipment, surgical instruments, and patient monitors.
- Industrial & Power Tools: Rugged battery packs for test equipment, inspection instruments, and field tools.
- Military & Defense: Tactical communications, field lighting, and ruggedized portable electronic devices.
- Emergency & Security: Emergency exit lighting, alarm system backups, and automated building controls.
- Robotics & Automation: AGV guidance backup systems, automated sensors, and robotic sub-assemblies.
End-to-End OEM Engineering & Charger Matching
NiMH batteries accept high charge and discharge rates up to 1C, enabling rapid recharging in approximately 1 hour with appropriate charger design. To prevent overcharging and ensure maximum cycle life, Cell-Con provides full-system matching with intelligent CC/CV and delta-V (-ΔV) sensing battery chargers custom-tuned to your battery pack.
Need a Custom NiMH Battery Pack Engineering Review?
Consult directly with our experienced engineering team to discuss your custom battery pack specifications, voltage requirements, enclosure design, and production timelines.
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