Understanding Certifications for Custom Battery Packs

Understanding Certifications for Custom Battery Packs

Custom battery packs are designed to meet specific application requirements, making them highly specialized solutions. At Voltaplex, we develop custom battery packs with unique features, including different cell chemistries, Battery Management Systems (BMS), and other tailored components. Given this customization, these batteries do not come pre-certified. In this article, we will discuss how certification works for custom battery packs, the steps involved, and what customers should consider before seeking certification.

Why Custom Battery Packs Are Not Pre-Certified

Unlike off-the-shelf batteries, custom battery packs are engineered for specific needs. Since each design varies in terms of cells, BMS, housing, and safety features, they cannot carry pre-existing certifications. Certification is a process that applies to a finalized product configuration, which means that every new design requires independent testing and approval.

Shipping and Sample Testing Before Certification

Although our custom battery packs are not certified upfront, Voltaplex can still ship samples to customers for validation. This allows customers to:

• Verify that the battery meets technical specifications and performance expectations.
• Identify any necessary design modifications before pursuing certification.
• Assess real-world operation in their intended application.

By testing a sample first, customers can ensure that all parameters are met before proceeding with the often costly and time-consuming certification process.

Compliance with Industry Standards and Certifications

While custom battery packs are not pre-certified, Voltaplex builds them in compliance with relevant safety and performance standards. This means that once a final design is selected, the battery can undergo formal certification through the appropriate regulatory bodies. Below are some of the key certifications that apply to custom battery packs:

1. UN 38.3 - Transportation Safety

• Required for lithium battery transportation globally.
• Ensures the battery can withstand conditions such as altitude simulation, vibration, shock, and thermal extremes.
• A must-have for shipping batteries by air, land, or sea.

2. UL 2054 / UL 62133 - Electrical Safety

• Ensures the battery does not pose a fire or electrical hazard.
• Required for consumer electronics, medical devices, and industrial applications.
• UL 2054 applies to standalone batteries, while UL 62133 covers rechargeable cells and batteries.

3. IEC 62133 - International Safety Standard

• Regulates safety for lithium-ion and nickel-based rechargeable batteries.
• Used widely in Europe and other global markets.
• Ensures safe design, component reliability, and proper construction.

4. PSE Certification - Japan

• Required for selling batteries in Japan.
• Ensures compliance with Japan’s Electrical Appliance and Material Safety Law.
• Demonstrates that the battery meets safety, quality, and reliability standards.

5. BIS (Bureau of Indian Standards) - India

• Mandatory for lithium-ion batteries sold in India.
• Ensures compliance with Indian safety and performance standards.
• Helps prevent substandard batteries from entering the Indian market.

**6. CE Marking - European Compliance. **

• Required for batteries used in products sold in the European Economic Area (EEA).
• Confirms compliance with health, safety, and environmental protection standards.
• Important for manufacturers exporting battery-powered products to Europe.

7. KC Certification - South Korea

• Required for lithium-ion batteries sold in South Korea.
• Ensures compliance with Korea’s Electrical Appliances and Consumer Goods Safety Control Act.
• Demonstrates that the battery meets safety, quality, and reliability standards.
• Required for batteries used in wireless electronic devices.
• Ensures compliance with electromagnetic interference (EMI) regulations.
• Necessary for consumer electronics and communication equipment.

Who Covers Certification Costs?

Certification costs typically fall under the responsibility of the customer. Additionally, during certification, batteries are subjected to rigorous testing, including destructive testing, meaning multiple battery samples will be required. Customers should factor in both certification fees and the cost of the batteries used in the testing process.

Below is a table outlining the approximate costs of various certifications:

By engaging early in the design phase, customers can plan for certification expenses and avoid unexpected costs later.

Certification costs typically fall under the responsibility of the customer. Because every custom battery pack requires unique testing, the costs vary based on:

• The type of certification required (e.g., transportation, safety, or performance).
• The regulatory region (e.g., North America, Europe, or Asia).
• The specific testing procedures needed for the application.

By engaging early in the design phase, customers can plan for certification expenses and avoid unexpected costs later.

When Should Customers Consider Certification?

Before applying for certification, customers should ensure the following:

1. Finalized Battery Specifications – Defining the voltage, capacity, and power requirements ensures that the correct battery design is tested.
2. Intended Application – Certification requirements depend on whether the battery is for consumer electronics, medical devices, industrial use, or transportation.
3. Regulatory Requirements – Different markets require different certifications. Understanding the target regions helps in selecting the appropriate standards.
4. Safety Features – Proper thermal management, overcharge protection, and short-circuit prevention are essential for passing certification tests.
5. Projected Volume – If large-scale production is expected, certification becomes a necessary investment to ensure legal compliance.

Custom battery packs are designed to meet specific needs, making pre-certification impractical. However, Voltaplex ensures that all custom batteries adhere to industry standards, enabling them to be certified once finalized. Customers can receive samples for validation before committing to the certification process. While the cost of certification is typically borne by the customer, planning ahead and understanding regulatory requirements can help streamline the process.

If you need assistance in designing a custom battery pack that can meet certification standards, contact Voltaplex today to discuss your project!