Custom pouch battery packs: applications, slim formats and selection
Pouch packs run thin and can be shaped to unusual spaces. They suit wearables, portable medical devices, smart-home products, consumer electronics and any product where thickness is the constraint. We design, build and deliver to your capacity, size and interface.
Applications
Where this form factor fits
The pouch format keeps thickness under control and can follow the internal shape of the product, which matters wherever slimness and fit are hard requirements. Capacities are usually modest but tolerances, protection-board layout and routing demand close attention — we tailor the outline and structure to your three-dimensional limits and connector positions.
Portable medical devices
Smart-home devices
TWS earbuds and charging cases
Handheld terminals and scanners
Ultra-thin instruments
Card-format devices
Checklist
What to confirm before selection
Tell us these details and we will select the option that balances performance and cost for you.
| Item | Description |
|---|---|
| System voltage | From compact low-voltage platforms to multi-series, set by the host product |
| Capacity range | Built to your requirements from 0.1 Ah to 600 Ah, confirmed per model |
| Discharge requirement | Continuous and peak rates matched to the duty cycle, per model |
| Structure & interface | Thickness, outline, protection-board layout and connectors customised to the mounting space |
| Certification & transport | 17 certifications and reports held (existing models): CE / IEC 62133 / UL 2054 / RoHS / REACH etc.; applicability confirmed per model and target market |
Note: the certifications and reports above were obtained for existing models. Other models are handled per your target market and specifications — existing reports are provided directly, and new items are applied for by our team together with you.
The above describes the general matching logic only. The final selection is made by us — your requirements come first, and we work to reduce your cost as far as safety allows.
FAQ
Common questions
Can you meet the thickness our product requires?
Yes. Give us the maximum thickness, the available footprint and the connector position, and we confirm the format, matching your product structure as closely as the capacity requirement allows.
Do you build small, shaped packs?
Yes. Capacity starts from 0.1 Ah and is built to your requirement; shaped outlines are assessed from drawings or a sample. Samples follow the same technical and inspection standards as production.
How do pouch and prismatic aluminium-shell differ?
Both can be square or rectangular — the difference is the enclosure. Pouch batteries are heat-sealed in aluminium-plastic film: the battery carries no structural load, so packs can be thin or shaped. Prismatic aluminium-shell batteries are welded in a metal case that doubles as the structural member, so single-unit capacity can be made larger. Which one fits is decided by us against your space and capacity requirements.
What certification is needed for export?
CE / IEC 62133 / UL 2054 / RoHS / REACH have been passed, and the applicable items are confirmed per your target market and model.
Pouch battery pack customisation: thickness set by your space, outline following your structure
Tell us the device thickness limit, the shape of the usable space, capacity and runtime, operating temperature and cycle requirement — we select the pouch format, fix the outline dimensions and tab positions, and deliver BMS configuration, swell-force management and mounting-structure recommendations.