Battery technology plays a crucial role in the performance, safety, and reliability of modern applications, from drones and robotics to medical devices and e-mobility. However, designing an efficient and compliant battery pack requires careful consideration of chemistry, form factors, power management, and regulatory standards.
This article, based on Dan-Tech Energy’s recent webinar, covers key aspects of battery design, battery management systems (BMS), lithium-ion vs. LiPo technology, and certification requirements—all essential for businesses looking to develop optimized energy solutions. View the full webinar recording here.
Why Battery Design Matters
A battery is more than just an energy source—it directly impacts the efficiency, longevity, and market success of a product. Poor design decisions can lead to overheating, premature failure, or even regulatory roadblocks that delay production and shipment.
The three core factors influencing battery design are:
- Performance – Maximizing energy output, lifespan, and charge cycles.
- Safety – Preventing thermal runaway, overheating, and power surges.
- Compliance – Meeting international shipping and certification standards to avoid supply chain disruptions.
Custom vs. Off-the-Shelf Batteries: Making the Right Choice
Many assume that off-the-shelf batteries are the simplest solution. While this may be true for consumer electronics, industries requiring high reliability, unique form factors, or strict certifications often need a custom battery pack.
Why choose a custom battery?
- Optimized for your product – Tailored to fit specific space, weight, and performance requirements.
- Full cost control – Enables precise control over the bill of materials (BOM) and production costs.
- Regulatory readiness – Custom packs can be designed with pre-certified components, reducing approval time.
- Enhanced safety and efficiency – Allows thermal management strategies and cell balancing, improving reliability.
For companies developing robotics, UAVs, medical devices, or industrial solutions, investing in a custom battery often translates to better performance, lower risks, and long-term cost savings. Learn more about how custom lithium battery packs enhance UAV performance.
Key Battery Chemistries: Understanding the Fundamentals
The chemistry of a battery determines its energy capacity, discharge rate, lifespan, and safety features. Here’s how the most common rechargeable battery types compare:
Li-Ion vs. LiPo: Which One Should You Choose?
- Li-Ion (NMC/NCA) batteries are known for their high energy density and longevity, making them ideal for robotics, medical devices, and industrial applications.
- LiPo (Lithium Pouch) batteries, while lightweight and capable of high discharge rates, are more mechanically sensitive and require strict power management.
For a deeper dive learn more in our article Li-Ion vs. LiPo.
Battery Form Factors: Cylindrical vs. Prismatic vs. Pouch Cells
Selecting the right battery form factor is crucial for integration and efficiency:
Cylindrical Cells
✅ High mechanical stability
✅ Efficient thermal management
✅ Widely available and reliable
❌ Takes up more space than pouch cells
Prismatic Cells
✅ Compact design
✅ Preferred for energy storage and EVs
❌ Can experience expansion issues over time
Pouch Cells (LiPo)
✅ Flexible shape
✅ Higher discharge rates
❌ Risk of swelling and mechanical damage
To avoid unexpected failures, ensure that your BMS properly regulates battery behavior. Learn more about assembling a safe Li-Ion battery pack with a BMS in our step-by-step guide.
Battery Management Systems (BMS) and Safety Considerations
A Battery Management System (BMS) is responsible for safety, monitoring, and energy efficiency. Key functions include:
- Protection Circuit Module (PCM) – Prevents overvoltage, overcurrent, and overheating.
- State of Charge (SoC) Estimation – Uses coulomb counting to track battery levels.
- Cell Balancing – Ensures uniform performance across all cells (Passive vs. Active balancing).
- Communication & Monitoring – Provides real-time battery health data..
There are two primary types of battery protection:
- Protection Circuit Module (PCM): Basic safety protection without communication features.
- Battery Management System (BMS): Advanced monitoring, diagnostics, and control.
For a detailed breakdown, read our guide on PCM vs. BMS: Which One Does Your Battery Need?
Navigating Certification & Compliance
Regulatory approval is one of the most critical (and often overlooked) aspects. Key certifications include:
UN 38.3
Required for battery transport (air, sea, land).
IEC 62133
Essential for consumer and industrial applications.
UL 1642 / UL 2054
U.S. safety standards for lithium batteries.
CE Marking
Required for products sold in the EU.
Battery ID (2024 Regulation)
Tracks battery lifecycle and ensures proper recycling.
Failing to meet these standards can prevent your product from reaching the market. To avoid costly delays, it’s best to design with certification requirements in mind from the start.
Final Thoughts
Want to explore the topic further? The full webinar recording is available here
Ready to take the next step? Submit your desired battery pack parameters, and we’ll help you design a custom battery solution optimized for your project’s needs.
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