Project Voltage
12.8V–96V custom
Custom LiFePO4
Battery Pack
Manufacturer
PackForge Energy manufactures custom LiFePO4 battery packs and modules for B2B energy storage, backup power, industrial equipment, light mobility, rack systems and field power applications.
From cell selection and smart BMS configuration to enclosure direction, pack assembly, electrical testing, certification coordination and export documentation, your project is handled through our engineering-to-production workflow.
Send your project brief and we’ll prepare a LiFePO4 battery configuration direction within 1 working day.
Manufacturing Strength Behind Every Project
Practical production resources and engineering support for custom lithium battery pack projects.
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Daily Export
Engineering Response
Configuration direction within 1 working day
Production Mode
Sample-to-batch in one workflow
Export Documents
UN38.3 / MSDS / SDS / Class 9 DG
BMS Options
Standard / smart BMS / CAN / RS485
Project Scope
OEM / ODM custom LiFePO4 battery packs
Why Engineering Teams Choose PackForge
Custom LiFePO4 projects are not only about voltage and capacity. OEM buyers need traceable cells, stable BMS selection, sample-to-batch control, export documentation and a supplier that can be held accountable.
Differentiator 1 — Engineering Response Within 1 Working Day
Your project brief is reviewed by our engineering team, and we provide a preliminary LiFePO4 configuration direction or clarification questions within 1 working day after receiving complete project information.
Differentiator 2 — Project-Approved Cell Selection
Cell selection is reviewed per project based on capacity, cycle life, lead time, certification pathway, BOM cost and customer approval. We support both LiFePO4 prismatic and cylindrical sources, with brand selection confirmed in writing before sample assembly.
Differentiator 3 — Sample-to-Batch Control
From sample development to pilot batch and batch production, your LiFePO4 pack specification is controlled under one workflow to reduce specification drift between prototype approval and production.
Differentiator 4 — Engineering-Led Review, Not Spec-Blind Quoting
We review voltage, capacity, discharge current, BMS, enclosure, connector, charger, certification and export requirements before quoting, so the proposed pack direction is tied to real project conditions.
Differentiator 5 — Export Documentation Planned Early
UN38.3, MSDS / SDS, Class 9 DG packaging, labels and destination-market documentation are reviewed before shipment planning, not after production is finished.
Differentiator 6 — Inspection and Traceability Support
Cell batch information, BMS records, assembly date, test records and pre-shipment inspection can be reviewed for batch projects according to the agreed quality control process.
Pack Types We Manufacture
Different B2B projects require different pack structures. PackForge reviews the pack type based on voltage, capacity, discharge current, communication, enclosure, connector, installation and documentation requirements.
Pack Type 1 — Low-Voltage Plastic / Metal Case Packs
12.8V and 25.6V LiFePO4 battery packs for backup power, portable systems, small industrial equipment and selected off-grid applications.
Typical project direction:
- 12.8V / 25.6V
- 50–200Ah
- ABS or metal case
- Standard or smart BMS
- Connector and charger review
Pack Type 2 — 48V / 51.2V Rack & Wall-Mount Packs
48V and 51.2V LiFePO4 packs for energy storage, backup power, telecom-style power systems, rack systems, light mobility and industrial power applications.
Typical project direction:
- 48V / 51.2V
- 50–200Ah
- Rack / wall-mount / front-terminal design
- CAN / RS485 optional
- Parallel expansion review
Pack Type 3 — High-Capacity Prismatic Modules
LiFePO4 battery modules using prismatic cells for projects requiring higher capacity, longer runtime and stable DC output.
Typical project direction:
- 51.2V and above
- 200Ah–300Ah+ cells
- Busbar design
- Fuse strategy
- Module / cabinet structure
- Service access review
Pack Type 4 — Equipment-Integrated Custom Enclosure Packs
Project-specific LiFePO4 battery packs designed around available equipment space, connector position, cable harness, enclosure structure and installation requirements.
Typical project direction:
- 24V / 48V / 72V / 96V
- Custom enclosure
- Connector and cable routing
- Mounting structure
- IP / service access review
Reference Configurations for B2B Battery Projects
The configurations below are reference directions for early project discussion. Final voltage, capacity, BMS, enclosure, connector, testing and documentation scope depend on the application, load profile, installation space and destination market.
| Project Type | Nominal Voltage | Typical Capacity | Approx. Energy | Cell Direction | BMS Direction | Structure Focus |
|---|---|---|---|---|---|---|
| Small backup power pack | 12.8V / 25.6V | 50–200Ah | 0.6–5kWh | LiFePO4 prismatic or cylindrical | Standard / smart BMS | ABS or metal case |
| Portable field power module | 12.8V / 25.6V | 20–100Ah | 0.25–2.5kWh | LiFePO4 cylindrical / prismatic | Over-current and temperature protection | External module or case-mounted pack |
| 48V storage pack | 48V / 51.2V | 50–200Ah | 2.5–10kWh | LiFePO4 prismatic preferred | Smart BMS, RS485 / CAN optional | Metal case / rack direction |
| High-capacity module | 51.2V | 200–300Ah+ | 10–15kWh+ | LiFePO4 prismatic | Smart BMS with communication | Module / cabinet structure |
| Industrial equipment pack | 24V / 48V / 72V | Project-based | Project-based | LiFePO4 cylindrical / prismatic | High-current BMS, fuse review | Rugged enclosure and cable routing |
| Low-speed mobility platform | 48V / 60V / 72V | Project-based | Project-based | LiFePO4 when cycle life and stability are prioritized | Peak current and thermal protection | Fixed / removable pack |
| Rack / telecom-style pack | 48V / 51.2V | 50–150Ah | 2.5–7.5kWh | LiFePO4 prismatic | CAN / RS485 / parallel review | Rack case, front terminal, service access |
Choose LiFePO4 when your project prioritizes cycle life, thermal stability and stable output.
LiFePO4 is often the stronger direction for ESS, backup power, industrial cycling, rack systems and projects where safety margin and long service life matter more than maximum energy density.
Best Fit
ESS, backup power, industrial cycling, rack systems
Strength
Long cycle life, high thermal stability, low maintenance
Main Trade-Off
Larger and heavier than NMC
Cycle life
Long
Thermal stability
High
Energy density
Medium
Maintenance
Low
In-House Engineering & Quality Control
PackForge manages LiFePO4 pack development through a controlled workflow covering pack engineering, BMS configuration, testing, quality control and export documentation.
Pack Engineering
We review cell format, series-parallel structure, BMS rating, connector layout and enclosure direction before sample build.
Cell Selection
S/P Structure
BMS Rating
Connector Layout
Enclosure Fit
Testing & Quality Control
Each custom pack can be checked against agreed electrical, mechanical and shipment requirements before delivery.
IR Check
Capacity Test
Charge / Discharge Test
BMS Protection Check
Final QC
Export Documentation
Documentation direction is reviewed based on cell model, pack structure, destination country and shipping method.
UN38.3
MSDS / SDS
Class 9 DG
Battery Labels
IEC / UL / CE Pathway
Anonymized LiFePO4 Project References
The examples below are anonymized project references showing typical LiFePO4 battery pack programs PackForge is set up to support for OEM/ODM customers. Customer names are withheld for confidentiality.
Project Reference 1 — 51.2V Rack backup Power Packs
Customer Type:
Telecom and backup power system integrator
Target Region:
Europe
Application:
Rack-mounted backup power system
Configuration:
51.2V 100Ah LiFePO4 rack battery pack
Approx. Energy:
5.12kWh per pack
Cell Direction:
Prismatic LiFePO4 cells
Pack Structure:
16S1P prismatic cell structure
BMS Direction:
Smart BMS with RS485 / CAN communication
Enclosure Direction:
3U / 4U metal rack case with front terminals
Pilot Stage:
12 sample units for system integration and communication testing
Batch Direction:
200–500 units per batch after validation
Documentation Direction:
UN38.3, MSDS / SDS, Class 9 DG shipping documents, IEC 62133-2 coordination when required
Key Challenge:
Parallel operation review, inverter communication matching, front-terminal layout and export documentation alignment
Project Reference 2 — 51.2V 200Ah Off-grid Storage Module
Customer Type:
Off-grid solar equipment OEM
Target Region:
Australia / New Zealand
Application:
Small commercial off-grid energy storage
Configuration:
51.2V 200Ah LiFePO4 battery module
Approx. Energy:
10.24kWh per module
Cell Direction:
High-capacity prismatic LiFePO4 cells
Pack Structure:
16S1P 200Ah prismatic cell structure
BMS Direction:
Smart BMS with CAN / RS485 communication for inverter compatibility
Enclosure Direction:
Metal case or cabinet-integrated module
Pilot Stage:
6–10 units for inverter matching and site testing
Batch Direction:
80–150 units per batch after system validation
Documentation Direction:
UN38.3, MSDS / SDS, Class 9 DG shipping documents
Key Challenge:
Inverter communication matching, enclosure heat spacing, batch consistency and long-distance ocean freight packaging
Project Reference 3 — 24V Industrial Cleaning Equipment Battery
Customer Type:
Industrial floor cleaning equipment manufacturer
Target Region:
Southeast Asia
Application:
Lead-acid replacement battery for floor cleaning equipment
Configuration:
25.6V 80Ah LiFePO4 custom battery pack
Approx. Energy:
2.05kWh per pack
Cell Direction:
LiFePO4 prismatic or cylindrical cell structure
Pack Structure:
8S configuration, customized according to equipment compartment
BMS Direction:
High-current BMS with temperature monitoring and charger matching
Enclosure Direction:
Custom metal or reinforced plastic case
Pilot Stage:
3–5 units for fit, charger and runtime validation
Batch Direction:
300–800 units annual demand after pilot approval
Documentation Direction:
UN38.3, MSDS / SDS, battery label and export packaging
Key Challenge:
Compact battery compartment, high startup current, charger compatibility, vibration exposure and service access
From Sample to Batch Production
A controlled sample-to-batch workflow helps reduce specification drift between prototype approval and mass production.
01
Project Requirement Review
Typical timing: 1–3 working days after receiving complete project information.
We review voltage, capacity, load profile, discharge current, charger or inverter, battery space, connector, target market, certification needs and annual quantity.
02
Configuration Direction
Typical timing: 2–5 working days depending on technical complexity.
We define cell format, series-parallel structure, BMS rating, communication interface, enclosure direction, terminal layout and documentation path.
03
Sample Quotation & Drawing Confirmation
Typical timing: 2–5 working days after configuration direction is confirmed.
We provide a quotation based on selected cells, BMS, enclosure, connector, harness, testing, documentation and packaging requirements.
04
In-House Sample Assembly
Typical timing: around 20 working days for standard LiFePO4 configurations; 25–35 working days for complex BMS, enclosure or documentation requirements.
Samples are assembled in our facility, including cell grouping, BMS integration, wiring, insulation, enclosure fitting and basic electrical checks.
05
Testing & Customer Validation
Typical timing: 3–7 working days for internal checks before shipment; customer-side validation depends on the project.
We complete electrical checks and BMS protection verification before delivery. The customer validates fit, runtime, output, communication, charging behavior and equipment-side compatibility.
06
Batch Production & Export Delivery
Typical timing: 35–45 working days for standard batch production after sample approval; complex documentation, enclosure or material requirements may extend the schedule.
After sample approval, batch production follows the confirmed specification. QC, packaging, labeling and export documentation are completed before shipment.
LiFePO4 Battery Pack FAQ
Common questions for OEM and B2B LiFePO4 battery pack projects, including voltage range, cell source, BMS options, documentation, warranty and project fit.
Q1. What voltage range do you support for LiFePO4 battery packs?
Most LiFePO4 projects we review are within 12.8V, 24V, 48V, 51.2V, 72V and 96V. Other configurations can be reviewed based on application, quantity, BMS and enclosure requirements.
Q2. What cell sources can you support?
For LiFePO4 prismatic or cylindrical projects, cell source is reviewed based on capacity, cycle life, lead time, documentation scope, traceability and customer requirements. Specific cell model can be specified by the customer or recommended based on application requirements.
Q3. Can you customize the BMS?
Yes. We can review standard BMS, smart BMS, CAN, RS485, UART, Bluetooth, SOC monitoring, temperature protection and current rating based on project requirements.
Q4. Can you build 48V or 51.2V packs?
Yes. 48V and 51.2V LiFePO4 packs are commonly reviewed for energy storage, backup power, rack systems, industrial equipment and selected mobility platforms.
Q5. What is your typical MOQ?
MOQ depends on cell model, BMS configuration, enclosure requirements, connector customization and documentation scope. Sample orders and pilot batches can be discussed before mass production.
Q6. How long does sample production take?
Sample lead time is typically around 20 working days for standard configurations and 25–35 working days for projects involving complex BMS, enclosure, connector or documentation requirements.
Q7. Can you provide UN38.3, MSDS and shipping documents?
Yes. We support lithium battery export documentation including UN38.3, MSDS / SDS, Class 9 DG shipping documents, labels and packaging requirements based on selected cells, pack structure and shipping method.
Q8. Can you support IEC 62133-2, UL 2054 or CE documentation?
We can support certification pathway discussion and testing coordination for standards such as IEC 62133-2 and UL 2054 based on UL 1642-certified cells, CE, UKCA, PSE, KC, RoHS and REACH depending on target market, battery design and customer requirements. Final certification is completed with accredited third-party laboratories according to the confirmed testing scope.
Q9. What warranty do you provide for custom battery packs?
Standard pack-level workmanship warranty is usually 24 months for ESS and backup power packs, and 12 months for industrial equipment and mobility packs under defined operating conditions and proper installation. Final warranty scope is confirmed in the project agreement based on duty cycle, operating environment, quantity and quality requirements.
Q10. Can you sign an NDA before drawing exchange?
Yes. NDA can be signed before technical exchange when required. Customer drawings, wiring information, enclosure data and application details are handled as confidential project information.
Q11. What payment and shipping terms can you support?
Commercial terms are reviewed per project. EXW, FOB, CIF and DAP can be discussed for export orders, and payment terms are confirmed according to order size, production stage and customer requirements.
Q12. Do you sell retail replacement batteries?
We mainly support OEM/ODM battery pack projects, not one-piece retail replacement battery orders. If you have voltage, capacity, BMS, connector, enclosure and quantity requirements, we can review whether the project fits our workflow.