Custom lithium battery packs, from prototype to series production
One team owns cell selection, BMS integration, thermal and mechanical design, validation and manufacturing. You get a single point of accountability from first sample to series production.
- Prototype
- 4 weeks from design
- Minimum order
- Low MOQ for start-ups
- Capacity
- 500 MWh+ a year
- Partners
- 40+ OEMs build with us
Custom battery packs built for your duty cycle
Typical ranges below. We regularly build outside them when the application needs it.
Solar & C&I storage
Residential, commercial and industrial storage systems that pair with hybrid inverters for peak shaving, backup and diesel replacement.
Discuss a storage pack- Voltage
- 48 – 800 V
- Energy
- 5 kWh – 1 MWh
- Standards
- IEC 62619, IEC 62040
Telecom & data centres
Float-service rack modules for towers, shelters and server rooms, with SNMP monitoring and long calendar life.
Discuss a telecom pack- Voltage
- 48 V, 240 V DC
- Energy
- 5 – 100 kWh
- Standards
- TEC GR, IEC 62619
Industrial & material handling
Lead-acid replacement for forklifts, AGVs and floor cleaners, built for opportunity charging and multi-shift operation.
Discuss an industrial pack- Voltage
- 24 – 80 V
- Energy
- 2 – 40 kWh
- Standards
- IEC 62619, UL 2580 path
EV mobility · 2W, 3W, CV
Traction packs for scooters, motorcycles, e-rickshaws, cargo three-wheelers and light commercial vehicles. Fixed and swappable formats.
Discuss a mobility pack- Voltage
- 48 – 96 V
- Energy
- 1.5 – 15 kWh
- Standards
- AIS-156 Ph-II, AIS-038
Agriculture & off-grid
Rugged storage for solar pumps, cold rooms and rural microgrids, sealed against dust and humidity.
Discuss an agri pack- Voltage
- 24 – 48 V
- Energy
- 2.5 – 20 kWh
- Standards
- IEC 62619, IP65
Everything between the cell and the finished pack, in-house
Mechanical, electrical and thermal
- LFP and NMC cells in prismatic, cylindrical and pouch formats
- 3D CAD, FEA for vibration and drop, CFD thermal simulation
- Busbar, harness and connector design to your vehicle or cabinet
Matched and calibrated to your pack
- BMS chosen for your cells, voltage and duty cycle
- Protection limits, balancing and state of charge set up and calibrated on the line
- Communication set up for your vehicle, inverter or cabinet
Tested before your customers do
- In-house cycle, abuse, vibration, thermal shock and IP testing
- Certification support for AIS-156, IEC 62133, IEC 62619, UN 38.3 and BIS
- PPAP-style documentation and design failure analysis
How a project runs
From first conversation to series production, on one line and with one team.
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Design and prototype
Duty-cycle analysis, cell selection, BMS integration, thermal and mechanical design, then working prototypes.
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Validation
Cycle, abuse, vibration and IP testing in-house, with certification support for your target standards.
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Pilot batches
Small runs for pilots, trials and first customers, built on the production line.
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Series production
Volume manufacturing on the same line, with cell-level traceability and warranty support.
Low-MOQ prototype battery packs for new products
Green-tech start-ups get the same engineering and the same tests as our volume customers, at a quantity that fits a pilot.
Start your prototype-
4weeks
Design to prototype
Working samples built on the same line as volume packs.
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LowMOQ
Small batches
Pilots, trials and first customers, before you commit to volume. One cargo e-rickshaw project started with a 5-vehicle pilot.
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Free
Integration support
System-level help fitting the pack into your product.
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24h
Problem assessment
An engineer assesses every complaint within 24 hours.
OEM battery pack services: choose how much we build
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Build to print
- You bring
- Your drawings, specifications and test plan.
- We bring
- Industrialisation and manufacturing to your design.
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Co-development
Most common- You bring
- Your product, duty cycle and targets.
- We bring
- Shared engineering from concept to series production.
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Private label
- You bring
- Your brand, enclosure colour and packaging.
- We bring
- An existing Halovolt pack, built under your brand.
Results from customer deployments
EV mobility
Cargo e-rickshaw lithium battery: Ahmedabad case study
Challenge: Lithium packs that fit the battery space of new cargo e-rickshaws used for parcel delivery.
Solution: Custom-size 60.8V 132Ah LFP packs based on the Gati Cargo 132, with a 5-vehicle pilot before the fleet.
Solar & C&I storage
96 kWh solar storage for a Rajkot anodizing plant
Challenge: A new anodizing plant with no backup power, on a grid with frequent outages.
Solution: Two Vidyut 240 LFP cabinets (96 kWh) with 150 kWp of solar, chosen over a diesel genset.
Material handling
80V lithium forklift batteries for a Jamnagar OEM
Challenge: Battery swaps between shifts and a spare lead-acid battery for each of 40 three-shift forklifts.
Solution: 80V 400Ah LFP packs in a modified tray, on chargers that talk to the BMS, charged once a day.
Custom battery pack questions
What is the minimum order for a custom battery pack?
We build small batches for pilots, trials and first customers before you commit to volume, on the same line and with the same tests as volume packs. One cargo e-rickshaw project started with a 5-vehicle pilot.
Will Halovolt sign an NDA?
Yes. NDAs are available, so you can share drawings and specifications before you commit.
How long does it take to develop a custom lithium battery pack?
A working prototype takes 4 weeks from design. Validation and pilot batches follow, then series production on the same line, at 500 MWh+ a year.
Which chemistries and cell formats do you work with?
LFP and NMC cells in prismatic, cylindrical and pouch formats, chosen for your voltage, duty cycle and space.
Can you help with certification?
Yes. We run cycle, abuse, vibration, thermal shock and IP tests in house and support certification to AIS-156, IEC 62133, IEC 62619, UN 38.3 and BIS.
Which voltages and capacities can you build?
Typical ranges are 48–800 V and 5 kWh to 1 MWh for storage, 48 V and 240 V DC for telecom, 24–80 V for industrial equipment, and 48–96 V and 1.5–15 kWh for EVs. We often build outside these ranges.
Can we sell Halovolt packs under our own brand?
Yes. Under private label we build an existing Halovolt pack in your brand, enclosure colour and packaging.
Tell us what you are building
An application engineer, not a sales rep, reads every request. Have these details ready when we reply, and we can return a concept and a budget price faster.
- 01Voltage, capacity and peak current
- 02Available space and weight limit
- 03Duty cycle and operating temperature
- 04Target certifications and annual volume
Start an OEM project
Reply within 24 hours from an application engineer. Your details are used only for this enquiry.
An application engineer will reply within 24 hours.