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Capabilities

Turnkey Custom Battery Pack Engineering, Smart BMS Design, Regulatory Compliance & Automated Testing

Turnkey Power Solutions for Global Original Equipment Manufacturers

Cell-Con, Inc. provides end-to-end custom battery engineering and manufacturing capabilities for demanding global OEM applications. With over 40 years of specialized power electronics expertise, our Bedford, Pennsylvania facility delivers ISO 9001 certified battery assemblies, intelligent Battery Management Systems (BMS), rigorous safety testing, and reliable supply chain management tailored to medical, military, robotics, and industrial procurement standards.

Custom Smart Battery Pack Design and Circuit Board Engineering

Custom Product Engineering & BMS Design

Upon receiving your target product specifications and power requirements, our senior engineering team manages every phase of battery development — from initial electro-chemical cell selection and circuit layout to custom mechanical housing integration and final delivery. We specialize in designing intelligent PCB protection circuits and advanced Battery Management Systems (BMS) to guarantee system reliability and extended cycle life.

From a mechanical perspective, our engineering team custom-designs durable plastic or metal enclosures engineered for harsh industrial environments, ensuring optimal internal thermal management and seamless physical engagement with your host device. Utilizing state-of-the-art in-house 3D printing and rapid prototyping, physical functional samples are produced rapidly for client evaluation and field fit-checks prior to tooling investment.

Smart BMS & Fuel Gauge Architecture
SMBus, I2C, HDQ & CANbus Protocols
Rapid In-House 3D Prototyping
Thermal & Mechanical Mold Tooling
Battery Regulatory Compliance Testing for UL and UN 38.3 Certifications

Regulatory Safety Compliance & Certification

Global markets require strict compliance with international battery safety standards. When your project demands third-party agency certifications, Cell-Con manages the complete regulatory qualification process from initial document preparation to final certificate issuance. Backed by decades of successful agency submittals, we streamline complex compliance requirements to eliminate market entry delays.

Our in-house engineering lab builds precise test samples manufactured under strict production controls to meet specific laboratory protocols. We maintain longstanding partnerships with leading globally recognized test laboratories, facilitating efficient processing for UL (UL 1642, UL 2054, UL 60601-1 medical), IEC 62133, UN/DOT 38.3 transport safety, and CE mark approvals.

UN/DOT 38.3 Transport Safety
UL 1642 & UL 2054 Compliance
UL 60601-1 Medical Standards
IEC 62133 International Safety
Automated Test Equipment ATE for Quality Control and Battery Cycling

Automated Quality Testing & Traceability (ATE)

Quality and field reliability are non-negotiable. Cell-Con operates an advanced fleet of custom Automated Test Equipment (ATE) engineered specifically for high-precision battery pack diagnostic inspection. Every single custom battery pack manufactured in our USA facility undergoes 100% automated end-of-line electrical and functional verification prior to packaging.

Our automated systems validate critical operating parameters including open circuit voltage (OCV), charge overvoltage thresholds, discharge overcurrent limits, fast-charge communication, thermistor temperature accuracy, and pack internal impedance. For smart packs, our ATE units verify digital communications (SMBus, I2C, HDQ, CANbus), fuel gauge calibration, electronic serial numbers, date of manufacture (DOM), relative state of charge (RSOC), and LED display functionality. All test records are stored in a centralized database for permanent component-level traceability.

100% Automated End-of-Line Testing
SMBus / CANbus Data Verification
Overcurrent & Overvoltage Protection Checks
Database Serialized Quality Records
Stocked Inventory of Lithium Ion LiFePO4 and Medical Battery Chargers

Stocked Inventory & Global Supply Chain Solutions

To eliminate long manufacturing lead times for standard power accessories, Cell-Con maintains a robust inventory of high-performance battery chargers and smart battery packs ready for immediate dispatch from our U.S. distribution center. Our charger line covers Lithium-Ion, LiFePO4, NiMH, and Lead Acid chemistries spanning power outputs from 15W to 300W.

Many of our standard chargers hold medical-grade UL 60601-1 safety certifications, allowing immediate deployment in clinical applications. For OEM partners with high-volume or recurring demands, we offer flexible blanket purchasing agreements and scheduled release programs to ensure stable, just-in-time delivery. When modifications are required (such as custom output cables, specialized connectors, or unique charging profiles), our assembly team implements modifications rapidly with minimal impact on lead time.

USA Warehouse Ready-to-Ship Stock
UL 60601-1 Approved Medical Chargers
OEM Blanket Orders & JIT Schedules
In-House Cable & Connector Customization

Require Custom Engineering for Your Battery Application?

Connect directly with Cell-Con's application engineering team. We review project specs, evaluate custom cell chemistries, and deliver high-reliability custom battery solutions optimized for global OEM compliance.

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