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Custom Battery Packs

Sager Electronics specializes in the design, engineering and assembly of custom battery packs and comprehensive battery systems as well as standardized batteries for a wide range of markets and applications.

Our custom solutions are assembled in the USA from our 18,000 sq. ft. facility centrally located in Lisle, Illinois. Our Battery Solutions Center (BSC) is ISO 13485:2016, AS9100D and ISO 9001:2015 certified. The internationally recognized certification affords Sager’s battery solution customers the confidence of knowing their battery partner adheres to established process controls and procedures, and has the technical know-how that is paramount to success. Sager’s Battery Solutions Center delivers safety, reliability, robustness and quality that only comes from excellence in training, adherence to best practices, implementation of cutting-edge tools, and a dedicated team with decades of experience. 

Supplier Partnerships

As an authorized value-add reseller of many of today’s top battery manufacturers, Sager is continuously exposed to the latest advancements in technology and product road-maps from our Factory Floor Battery using Battery Technology dedicated suppliers. Sager’s Battery Solutions Center offers all commercially available battery chemistries including Lithium Ion, LiFEPO4 (LFP), Lithium Titanate Oxide (LTO), Lithium Primary, Nickel-based, Sealed Lead Acid (SLA) and Pure Lead. These partnerships are an invaluable advantage for our customers. 

Advanced Capabilities

Sager’s BSC is expertly qualified in the integration of the most innovative technologies into our customers’ battery systems. Our in-house team of engineers and battery technicians design, develop and produce custom battery assemblies and complex Battery Management Systems (BMS) containing advanced features such as:

  • On-board charging circuitry
  • SMBus communication
  • CAN-bus communication
  • I2C communication
  • Fuel gauge
  • Thermal monitoring, control & shutoff
  • Cell balancing
  • Impedance tracking
  • Charge time
  • Bluetooth, Wi-Fi & cellular integration
  • Battery life and overall battery health

SAFETY:

  • Min. double Insulation between opposite poles
  • Thermal barriers in between series LI-Ion Cells
  • Redundant safety devices to shut down batteries if adverse Conditions Exist
  • Thermal management to protect battery
  • Protective Cases when battery is user accessible
  • Avoid elevated temps
  • Cell spacing to protect from thermal migration
  • Use of thermal dissipating materials
  • Programmed battery shut down when you reach EOL

PACK ASSEMBLY CAPABILITIES:

  • Customized Battery charging & top-off
  • Ultrasonic joint design and sealing equipment
  • Smart battery programming development and installation
  • Custom packaging
  • Computer-controlled spot-welding
  • Passive cooling integration
  • Semi-Automated potting & encapsulationCustom Battery Solution

TEST & PRE/POST QUALIFICATION CAPABILITIES:

  • Cycle testing – Battery
  • Life cycle testing – Cell
  • Load testing
  • Environmental testing
  • 3-D printing for quick prototyping

Test & Qualification Capabilities

QUALITY:

  • ISO 13485:2016, ISO 9001:2015, & AS9100D certified
  • Quality planning starts at the very beginning. Proactive approach
  • 100% functionally tested. All test data is electronically stored for easy access
  • All cells are 100% tested and matched
  • Tightly controlled In-process inspection at any critical step
  • Final QA audit for each production batch
  • Packaging is tested to withstand a 1M drop on 6 axis
  • All crimps are tested and verified
  • Perform capacity test on a sample of in-bound cells and batteries

PROGRAM MANAGEMENT:

  • Concept to production capability
  • Implementation of the latest tools for program tracking and Gantt charting
  • Controlled design process
  • Comprehensive documentation
  • Quick turn prototypes
  • Highly flexible scheduling and order management
  • Rapid time to market
  • Educational assistance (UN/DOT 38.3, UL, IEC, I-Safe)
  • JIT stocking programs

RESOURCES:

Agency testing and certification

UN Manual of Tests and Criteria, Sub-Section 38.3
IATA Lithium Battery Guidance Document

Recycling
For more information and to find a Call2Recycle drop-off location near you, call 1.800.822.8837 or visit www.call2recycle.org.

Have a custom battery requirement?
Complete our form and let us know how we can help.

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