Custom Assembled Ni-MH Battery Packs | Factory OEM Wide Temperature Solutions
Many electronic device developers cannot find ready-made standard AA, AAA or cylindrical cells that match internal installation space, voltage and standby power demands. At Weijiang Energy, we build tailor-made NiMH packs by combining our self-produced wide-temperature cells in series, parallel or mixed layouts. Based on our complete cell lineup (AAA500/600, AA1200/1300/2200, SC, C, D sizes), we adjust wire harness, connectors, outer casing and protection circuits to fit OEM hardware structures exactly.
We handle small prototype sampling and mass-volume production for brands across auto telematics, medical equipment, solar lighting, power tools and industrial sensors. Unlike trading companies without production lines, we own full cell manufacturing and PACK assembly workshops, which lets us control cell sorting, laser welding and aging test links to stabilize pack consistency.
1 Our Standard NiMH Cell Base For Custom Assembly
All packs are built with in-house produced cells, including regular and -40℃~85℃ wide-temperature variants. Core mass-production models available for pack assembly as below:
| Cell Size | Available Capacity | Standard Discharge Temp | Wide Temp Version | Cycle Life (IEC61951-2) |
|---|---|---|---|---|
| AAA | 500mAh / 600mAh | 0℃ ~ 60℃ | -40℃ ~ 85℃ | ≥500 cycles |
| AA | 1200 / 1300 / 2200mAh | 0℃ ~ 60℃ | -40℃ ~ 85℃(1200/1300) | ≥500 cycles |
| SC | 2600 / 2800 / 3300mAh | -20℃ ~ 70℃ | Optional wide temp formula | ≥500 cycles |
| C | 4000 / 5000mAh | -20℃ ~ 70℃ | Optional wide temp formula | ≥500 cycles |
| D | 8000 / 9000 / 10000mAh | -20℃ ~ 70℃ | Optional wide temp formula | ≥500 cycles |
2 Customization Solutions: 5 Adjustable Dimensions For NiMH Packs
We provide full customized service covering cell selection, internal layout, thermal protection, wiring connectors and outer packaging. The overview chart below shows all adjustable modules clearly:
All 5 Custom Modular Dimensions At A Glance
Industrial & vehicle-grade battery packs support full customization from internal cell performance to outer printed housing, match all unique equipment cavity and operating environment requirements.
2.1 Cell Performance & Specification Customization
A, AA, AAA, Sub C, C, D, F standard cylindrical cells; special custom square cells available.
Max runtime for stationary equipment, solar lighting & daily consumer devices.
Stable high current output for power tools, RC vehicles & garden machinery.
-40℃ ~ +85℃ stable discharge, dedicated for vehicle T-BOX & polar field devices.
Ultra long standby for remote sensors, smart locks & unattended monitoring gear.
2.2 Cell Series-Parallel Layout & Pack Shape
- Voltage & capacity matching: 3S1P, 4S2P, 6S1P and any custom series-parallel combinations to hit target output.
- Stick straight layout: Fit narrow long cavities like vehicle T-BOX internal space.
- Side-by-side flat layout: Thin portable devices such as beauty instruments & handheld scanners.
- Block stacked layout: Large capacity power tools, off-grid solar storage systems.
- Custom L-shape / plum blossom irregular layout for limited special installation space.
2.3 BMS / PCM Thermal & Safety Protection
Temperature monitoring sensor for vehicle & industrial high-low temp packs.
Auto current cut-off to avoid overheating under abnormal discharge.
Overcharge, over-discharge, over-current & short circuit four-way safety control.
I2C, SMBus digital communication for intelligent monitoring equipment.
2.4 Wire Harness & Custom Connectors
All wires use UL certified material, wire length & wire gauge fully adjustable based on your mainboard interface distance:
- Standard plugs: JST, Molex, AMP, Tamiya, XT60, XT90, EC5 for different current loads.
- Custom metal solder tabs, bare wire leads or special customized terminals as customer drawings required.
- Extra NTC temperature sensing wire can be added for vehicle T-BOX wide-temperature packs.
2.5 Outer Packaging & OEM Brand Marking
Multiple color options for visual product differentiation.
Shockproof integrated plastic shell for finished battery modules.
Print brand logo, model number, spec parameters & safety warning text.
Laser batch serial number for full production traceability.
3 Complete Custom Pack Order Workflow (Visualized)
Submit your voltage, capacity, size & application, engineers evaluate feasibility within 24h.
Provide cell layout drawing, BMS circuit diagram & 3D housing model for customer confirmation.
Make first article sample, complete charge-discharge, thermal shock & vibration test before delivery.
Mass produce after sample approval, full OQC inspection for every finished pack before shipment.
4 Main OEM Application Scenarios For Custom NiMH Packs
4.1 Vehicle T-BOX & Automotive Telematics Packs (Core Custom Line)
3S1P 3.6V AAA wide-temperature NiMH packs serve mandatory backup power for car TBOX units. After vehicle main battery cut-off, the pack keeps GPS positioning and eCall fault logs stored for 5~30 mins. The sealed anti-vibration assembly passes vehicle-grade vibration & thermal aging tests, full PPAP documents available for auto factory bidding.
4.2 Handheld Industrial Terminals & Data Scanners
Compact multi-cell NiMH assemblies deliver steady low-ripple current for inventory scanners, portable measuring equipment. Low self-discharge formula retains power during long shift standby.
4.3 Portable Medical & Home Healthcare Devices
Safe non-flammable NiMH custom packs for nebulizers, portable blood pressure machines and patient monitoring gear. No thermal runaway risk meets medical device safety standards, full MSDS & UN38.3 export files provided.
4.4 Solar & Outdoor Emergency Lighting Systems
Wide-temperature NiMH packs store solar power for garden lights, off-grid monitoring cameras and building exit emergency lamps. Strong temperature fluctuation resistance cuts field maintenance frequency.
4.5 Cordless Power Tools & Garden Equipment
High-drain SC/C/D combined packs supply sustained current for electric screwdrivers, small hedge trimmers. Optimized laser welding avoids loose terminals under frequent shock.
4.6 Smart Locks & Access Control Hardware
Miniature stacked NiMH assemblies fit narrow lock internal cavities, offering months-long standby power for touchless door access sensors.
4.7 Industrial IoT Unattended Sensors
Long-storage low self-discharge custom packs for factory workshop temperature detectors and outdoor soil/water monitoring stations.
5 Our Factory Pack Assembly Workflow (From Cell To Finished Pack)
| Process Step | Quality Control Standard |
|---|---|
| 1 Raw Cell Sorting | Automated OCV & internal resistance screening, cell voltage difference controlled within 5mV |
| 2 Electrode Welding | Fiber laser welding, no virtual solder to avoid overheating during discharge |
| 3 Insulation Assembly | EVA & ceramic insulation between cells to block heat spread |
| 4 Wire & Connector Mount | Fixed wire routing to prevent internal friction damage |
| 5 Protection Circuit Integration | PTC/BMS matching per customer discharge current demand |
| 6 Shrink Tube & Housing Forming | Custom brand printing available on outer sleeve |
| 7 Aging Cycle Test | 2 full charge-discharge cycles to verify capacity consistency |
| 8 Finished Product Inspection | Voltage, resistance, appearance & wire pull test before packaging |
6 Factory Strength & Global Certification Support
- 3 full automatic NiMH production workshops, annual cell output over 219 million units
- 300+ professional R&D and technical staff, independent electrolyte & wide temp material lab
- Complete reliability test lab: thermal shock, double 85 aging, vibration, drop, short-circuit extrusion tests
- Full global certificates: ISO9001, ISO14001, BSCI, CE, RoHS, REACH, UN38.3, MSDS, IEC62321
- Regulation (EU) 2025/40 Packaging and Packaging Waste Regulation( PPWR)
- Export to more than 60 countries across Europe, North America, Southeast Asia, Australia
- Support small batch prototype samples (flexible MOQ) and large OEM mass orders
- All test reports, spec sheets and certification files provided for customs clearance & product bidding
7 Why Our Custom NiMH Packs Beat Generic Suppliers
- Vertical integration: Self-produced cells + in-house PACK line, no third-party cell markup cost
- Exclusive -40℃~85℃ wide temperature cell formula unavailable from trading middlemen
- Automated cell sorting matching reduces long-cycle capacity attenuation
- Mature vehicle-grade pack manufacturing experience for TBOX & fleet monitoring equipment
- Free custom drawing & spec sheet design for OEM clients before mass production
- One-year limited warranty for all finished battery packs against raw material defects
Send Your Custom Ni-MH Pack Technical Requirements
Share your target device type, operating temperature range, required voltage & capacity, internal dimension limit and connector demands. Our battery design engineers will issue a customized pack drawing and factory quotation within 24 working hours.
WhatsApp: +8615089431104
Official Business Mail: Service@wejiangpower.com
Related Application Pages: Wide Temperature Ni-MH Tech Blog | Industrial IoT Ni-MH Batteries
