Frequently Asked Questions (FAQ)

Cell-Con specializes in custom smart battery packs, custom battery chargers, stock battery chargers, and power conversion systems. Our primary cell chemistries include Lithium-Ion (Li-ion), Lithium Iron Phosphate (LiFePO4), and Nickel-Metal Hydride (NiMH), engineered for medical, industrial, military, robotics, and oceanic applications.

All Cell-Con custom battery packs and charger systems are engineered, assembled, and quality-tested at our headquarters and manufacturing facility located in Bedford, Pennsylvania, USA. Domestic production guarantees rigorous ISO 9001 quality standards and reliable supply chain execution.

We serve original equipment manufacturers across high-reliability sectors, including:

• Life-critical portable and stationary medical devices
• Military, defense, and rugged field instrumentation
• Autonomous mobile robots (AMR) and industrial automation
• Material handling equipment and warehouse logistics
• Subsea, oceanographic, and aerospace data collection

Selection depends on key design constraints:

• Lithium-Ion (Li-ion): Highest energy density per unit weight/volume, ideal for compact medical and portable electronics.
• Lithium Iron Phosphate (LiFePO4): Exceptional cycle life (2,000–5,000+ cycles), high thermal safety, and stable voltage profile for heavy industrial and robotics use.
• NiMH: Cost-effective, simple shipping compliance, suited for applications requiring high charge acceptance or specialized cold-temperature operation.

To provide an accurate technical proposal, our engineering team requires operating nominal/peak voltage, continuous and pulse discharge current, runtime targets, maximum physical dimensions, operating ambient temperature range, and targeted regulatory certifications (e.g., UL 2054, UN 38.3, IEC 62133).

Yes. In addition to sub-100Wh handheld battery packs, Cell-Con designs high-capacity large-format lithium battery systems ranging from 300Wh to over 30kWh for industrial equipment, uninterrupted power supplies (UPS), and marine applications.

A Smart Battery Pack contains an integrated Battery Management System (BMS) with fuel gauge ICs and protection electronics. The BMS monitors cell voltages, current, temperature, state of charge (SoC), and state of health (SoH), while communicating with the host device over SMBus, I2C, or CANbus protocols.

Multi-layered safety protections include primary and secondary hardware protection against overvoltage, undervoltage, overcurrent, external short circuits, and overtemperature conditions. Thermal cutoff fuses and passive/active cell balancing are standard features in our lithium configurations.

We provide full design and documentation support for UN 38.3 transport safety testing, UL 1642, UL 2054, IEC 62133, UL 60601-1 (medical electrical safety), CE marking, and RoHS/REACH environmental compliance.

Yes. We offer standard stock chargers with universal AC input (90–264VAC) and UL approvals for rapid deployment, as well as fully custom desktop, wall-plug, or embedded charger designs optimized for custom battery charging profiles.

Yes. Our engineering facilities support low-volume rapid prototyping for design validation, seamlessly scaling to high-volume manufacturing programs with full lot traceability and quality control.