How to Specify a Custom Battery Pack: The 8 Questions Your Manufacturer Will Ask

The fastest custom battery projects are the ones where the customer arrives knowing the answers to eight questions. The slowest are the ones where those answers surface one at a time, each forcing a redesign. Whether you work with us or anyone else, here is what a battery manufacturer will ask — and why each answer shapes the pack.

1. What voltage does your system need?

The nominal voltage sets the series count — we build from 2S to 28S — and it should come from your powertrain and electronics, not from what packs happen to exist. If you are between two voltages, say so; that trade is exactly what custom design is for.

2. How long must it run, doing what?

Capacity follows from runtime, and runtime only means something against a load profile: how many watts, for how long, doing which tasks. "Four hours of operation" with a duty cycle attached is a specification. "A big battery" is not.

3. What are the peak loads?

Motors starting, transmitters keying, actuators slamming — peaks decide cell selection as much as capacity does. A pack sized only for average draw will sag exactly when the equipment needs it most, a failure mode we see often in ground vehicles.

4. What space and weight can you give it?

The envelope — dimensions, mounting, and the weight budget — determines the pack's geometry and often its chemistry. The earlier we see the CAD, the more battery fits in the space.

5. Where will it live?

Temperature range, vibration, dust, moisture, altitude. A lab pack and a field pack are different machines: our field packs are rated for operation down to −20°C and built ruggedized for platforms from UAVs to marine systems.

6. What must it connect to — power and data?

Connector standards, wire gauge, and the data side: should the pack report state of charge and health to your system? Our smart BMS speaks to common flight controllers including Pixhawk — here is what a BMS actually does and why you almost certainly want one.

7. How will it charge?

Charge time targets, available power at the charging site, and whether charging happens in the equipment or out of it. Fast charging — our packs reach full in as little as 30 minutes — is a system property of pack, BMS, and charger together, which is why we prefer to supply the complete power solution.

8. How many, and by when?

Prototype quantities and production volumes shape design choices from day one. We support both — first article through production scaling, engineered and manufactured in India.

Bring the answers, leave with a pack

If you can answer even five of these eight, you are ready to start a custom battery conversation. At Revogreen Technologies — 30,000+ batteries delivered across defense, drones, robotics, and medical devices — we will help you pin down the rest.

Start your battery specification →