At Voltaplex, we design and manufacture custom lithium battery solutions for industrial, mobility, robotics, medical, and energy storage applications. One question we frequently receive is about battery pack casing options — especially when moving beyond simple PVC wrapping toward more robust, waterproof, dustproof, or industrial-grade enclosures.
This article explains battery pack casing options, challenges of custom housings, our workflow, and how these decisions impact cost, safety, certification, and scalability. Whether you are planning a custom lithium battery, a custom lifepo4 pack, or a custom lion battery pack custom lithium battery solution, enclosure design is a critical part of success.
Example of a Voltaplex custom lithium battery pack using a standard industrial casing — a practical approach for early production before committing to custom tooling.
Why PVC wrapping is often used first
PVC wrapping is commonly used for:
• Prototypes and engineering validation
• Early production batches
• Cost-sensitive applications
• Projects still evolving mechanically
It allows flexibility while electrical, thermal, and BMS performance are being validated. Jumping directly into custom casing too early can result in expensive redesigns.
For most custom lithium battery projects, we recommend validating performance first, then investing in custom casing once specifications stabilize.
Example of a Voltaplex custom lithium battery pack using a PVC Wrapping — a practical approach for early production before committing to custom tooling.
Custom casing for samples — usually not recommended
Custom battery enclosures require tooling, which typically costs:
• Plastic moulds: roughly 5k to 20k USD depending on complexity
• Metal enclosures: generally lower cost but still application-dependent
This cost makes custom casing impractical for small sample quantities. At Voltaplex, we usually recommend:
PVC wrap or standard casing for prototypes
Custom enclosure only once volume production is confirmed
This approach reduces risk and shortens time to market.
Standard vs custom battery case sizes
There are no universal standard battery sizes because pack design varies widely:
Voltage range: 3.7V to 100V+
Cell types: cylindrical, pouch, prismatic LFP
Applications: robotics, ESS, UAVs, medical devices, industrial tools
Even when cylindrical cells like 18650 or 21700 are used, the total housing size depends on:
• BMS size and features
• Connector placement
• Thermal spacing
• Mechanical mounting
• Certification requirements
Some semi-standard housings exist (such as e-bike battery shells), but they rarely fit perfectly for custom lithium battery projects.
Challenges in custom battery pack casing design
Custom casing adds engineering complexity that customers often underestimate.
Thermal management
Heat dissipation becomes critical in high-power or energy storage systems.
Ingress protection
Waterproof or dustproof ratings (IP54, IP65, IP67) increase sealing complexity.
Mechanical integration
The enclosure must match the host device while protecting cells and electronics.
Certification impact
Housing design affects transport certifications (UN38.3) and safety approvals.
Cost and lead time
Tooling development can add several weeks to project schedules.
These factors apply whether designing a custom lithium battery, custom lifepo4 pack, or industrial ESS system.
Voltaplex custom LFP battery solutions
Voltaplex provides custom LiFePO4 battery solutions for:
Commercial energy storage systems
Robotics and automation
Marine and off-grid applications
Medical and industrial equipment
Benefits of LFP chemistry include:
Long cycle life
Improved safety
Thermal stability
Stable voltage profile
We support both cylindrical and prismatic LFP cells depending on energy density, thermal needs, and mechanical constraints.
Our end-to-end workflow typically includes:
Cell sourcing and validation
Mechanical design and casing optimization
BMS development and integration
Certification support
Mass production scaling
Technical diagrams and design workflow
In most custom battery casing projects, we work from technical documentation such as:
Mechanical CAD drawings
Block diagrams showing cell layout
Connector and wiring schematics
Thermal airflow diagrams
Ingress protection sealing designs
Typical casing development workflow:
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Electrical design finalized
-
Cell configuration confirmed
-
Mechanical envelope defined
-
Prototype casing (PVC or standard enclosure)
-
Customer validation
-
Tooling design and approval
-
Mass production
This structured approach minimizes risk and ensures performance reliability.
Plastic vs metal casing – quick comparison
Plastic casing advantages:
Lightweight
Flexible shapes
Good electrical insulation
Consumer-friendly appearance
Metal casing advantages:
Better heat dissipation
Higher structural strength
Often lower tooling cost for large packs
Preferred for ESS and industrial systems
Selection depends on application, environmental conditions, and production scale.
