A custom battery pack manufacturer designs, engineers, and produces battery assemblies tailored to a specific device or application rather than selling off-the-shelf cells. Emerging Power, based in Hackensack, NJ, provides end-to-end custom battery pack design and manufacturing for OEM and contract-manufacturer (CM) clients across commercial and military sectors.

Their solutions include BMS integration, PCB development, custom enclosures, automated testing, regulatory support, and global distribution all under one roof. With 120+ years of collective team experience, Emerging Power handles everything from initial design to UN/DOT-compliant shipping.

Emerging Power manufactures a wide range of custom battery chemistries to match different power, safety, and size requirements:

• Custom Lithium-Ion (Li-Ion) Battery Packs – high energy density for portable electronics and industrial devices
• Custom Li-Polymer (Li-Po) Battery Packs – slim, flexible form factors for wearables and drones
• Custom Lithium Iron Phosphate (LFP) Battery Packs – long cycle life and thermal safety for mission-critical applications
• Custom Lithium Primary Packs – non-rechargeable, ultra-long shelf life for asset tracking and IoT
• Custom Nickel Metal Hydride (NiMH) Packs – reliable mid-tier chemistry for medical and industrial use
• Custom Alkaline, Sealed Lead Acid, and Lithium-Thionyl Chloride packs also available

Emerging Power supplies custom battery packs across six key markets:

Medical: Portable diagnostic devices, patient monitoring equipment, and surgical tools requiring FDA-compatible, high-reliability power.
Military & Defense: ITAR-registered manufacturing for rugged, mission-critical battery systems meeting MIL-SPEC standards.
Drones & UAV: Lightweight, high-discharge Li-Po and Li-Ion packs built for maximum flight time and safety.
IoT Devices: Long-life primary lithium packs for sensors and connected devices that cannot be frequently serviced.
Asset Tracking & GPS: Low self-discharge batteries for GPS trackers and logistics hardware.
Smart Meters & Wireless Sensors: Energy-efficient packs designed for a decade-long service life in harsh environments.

Yes. Emerging Power is ITAR (International Traffic in Arms Regulations) registered, which means they are cleared to design and manufacture battery packs for defense, aerospace, and military applications requiring strict U.S. export control compliance.

They are also AS9100-2016 certified the aerospace and defense quality management standard and perform UN/ST 38.3 safety transportation testing in-house, ensuring every military-grade battery pack meets global shipping and safety regulations.

Smart battery design refers to battery packs embedded with a Battery Management System (BMS) an electronic circuit that monitors cell voltage, current, temperature, and state of charge in real time. This protects against overcharge, over-discharge, and short-circuit events while providing data communication to the host device.

Emerging Power offers full smart battery design services, including BMS development, PCB layout, custom firmware programming, and automated testing and programming. Their smart RRC battery packs support standardized communication protocols for military and industrial users.

Emerging Power follows a “Design for Safety Built with Quality” philosophy. Their compliance capabilities include:

• UN/ST 38.3 Safety Transportation Testing mandatory for shipping lithium batteries internationally by air, sea, or road
• AS9100-2016 quality management certification for aerospace-grade manufacturing
• ITAR registration for defense-related battery programs
• In-house compliance and regulatory consulting to help OEMs navigate UL, IEC, CE, and DOT requirements

Their dedicated regulatory resources page provides documentation support, making Emerging Power a single-source partner for both design and certification.

Lithium-Ion (Li-Ion) battery packs deliver higher energy density, making them ideal when weight and size are critical such as in drones, medical handhelds, and portable electronics. They typically offer 300–500 full charge cycles.

Lithium Iron Phosphate (LFP) packs trade some energy density for significantly better thermal stability, safety, and cycle life (often 2,000+ cycles). LFP chemistry is preferred for applications where longevity, reliability, and fail-safe operation matter most such as industrial systems, military power units, and stationary backup power.

Emerging Power engineers both chemistries and can help OEMs select the right one based on voltage requirements, discharge rate, operating temperature, and regulatory constraints.

Yes. Emerging Power supports both prototype and high-volume manufacturing. For early-stage development, they offer:

• 3D printing capabilities for rapid battery enclosure and housing prototyping
• Project management support to guide OEMs from concept through first-article testing
• Ultrasonic welding for precision cell and enclosure assembly at any scale

This makes Emerging Power well-suited for startups, R&D teams, and established OEMs launching new product lines who need a trusted custom battery pack supplier in the USA that can grow with their production needs.

Emerging Power is headquartered at 200 Holt Street, Hackensack, NJ 07601 and operates Monday through Friday, 9 AM to 5 PM EST. They can be reached at (201) 441-3590 or sales@emergingpower.com.

Beyond U.S.-based manufacturing, Emerging Power provides global manufacturing capabilities and worldwide battery distribution, making them a viable partner for OEMs and contract manufacturers (CMs) operating internationally. Their supply chain infrastructure supports compliant cross-border lithium battery shipments under UN/DOT transport regulations.

To start a custom battery project with Emerging Power, visit their Request a Quote page at emergingpower.com/request-a-quote/ and provide details such as your application type, required voltage and capacity (Wh/Ah), operating temperature range, form factor constraints, and target production volume.

Their engineering team will review your requirements and recommend the optimal chemistry, BMS configuration, and enclosure design. Early-stage projects are welcome Emerging Power’s project management team can assist from initial concept through regulatory certification and mass production ramp-up.