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Global Statistics Representing Custom Battery Pack Market Scenario

Custom battery packs’ specifications (shape & size) are personalized to meet the unique needs of the application. Each pack is inspected for defects or quality issues. Custom battery packs are made using nonferrous metals and minerals such as Li-Ion, Li-poly, Ni-Cd, Ni-MH, and Sealed Lead Acid. Increasing complexity and demand for clean energy have created a need for custom battery packs to provide a long span life in a compact form.

The industrial revolution has challenged the battery manufacturing industry to create competitive and sustainable custom solutions. Custom battery packs have seen rapid improvements in performance and cost due to extensive research and development activities in lithium-ion (Li-ion) batteries and prominent growth in developed economies. These investments by existing and new players have built a vast ecosystem; for instance, research institutes, manufacturers, and end-users such as automotive, electronic devices, and utilities have expanded the application range of custom battery packs. These batteries’ voltage and current are designed as per application for use in different combinations.

Custom Battery Packs — Gaining Momentum In The Growth Phase Of Product Lifecycle

The custom battery pack product is in its growing phase with the sudden transformation of fuel run automobiles into electric vehicles. The demand for battery and hybrid electric vehicles has tremendously increased around the globe. According to the International Energy Agency, the global sale of electric vehicles (EVs) hit a record 750,000 in 2016, and currently holds a global stock of 2 million units. EV sales increased by 63% in 2017 compared to 2016. The product has a significant opportunity ahead before it matures or becomes obsolete.

Demand For Custom Battery Packs To Trail Evolution Of BEVs and HEVs

The growing popularity of EVs is expected to translate to an upsurge in demand for custom-made batteries in the coming years. EVs are expected to account for 35% of all vehicles by 2024, largely driven by a steep decline in the cost of battery technology and decarbonization by governments worldwide.

As the demand for mobile computing and all-electric vehicles increases, existing battery technology poses a roadblock to future battery development. The existing technology is paving the way for the development of batteries that can compete and provide improvised performance similar to Li-ion batteries, bypassing the significant cost associated with production. For instance, Tesla Motors (TSLA) has underlined the clear demand for electric vehicles with new sales records every year; however, such vehicles require custom-made batteries, making them an expensive single component.

Battery Recycling & Waste Management

A key restraint is the battery recycling dilemma that manufacturers face.  Lithium battery technology registers tremendous demand from various industry verticals such as automotive, defense, aerospace, medical devices, and oil and gas instruments. Different recycling schemes will need to be in place to overcome the challenges associated with waste collection in landfills. With the boom of custom batteries, researchers and environmentalists are seeking novel solutions for improvements in the recycling process.

According to the U.S. Environmental Protection Agency (EPA), around 350 million rechargeable batteries are purchased every year in the U.S., and the number continues to grow exponentially. As mercury is also highly toxic, especially in vapor form, various governments have banned the use of mercury batteries in many regions.

The German government has designated around EUR 1 billion to support battery cell production, and Europe is expected to account for 30% of the global market share by 2030. The European Union organized the European Battery Alliance in 2017 to establish a competitive manufacturing value chain in Europe. This alliance is expected to conquer up to EUR 250 billion per year market from 2025.

Li-Ion to Account for the Largest Share of the Pie Among All Segments by Type

By product type, lithium-ion is expected to emerge as a potential segment for investment and grow at a CAGR of 8.2% during the forecast period, 2019–2026. Stringent regulations on the ban of mercury and cadmium are expected to drive the demand for custom batteries in automotive and portable device industries. The European Union Battery Directive (2006/66/EC) regulates manufacturing and accumulators in the European Union to protect human health and the environment from hazardous substances such as cadmium and mercury. 

The Lithium-ion (Li-ion) batteries segment was valued at USD 16,138 million in 2018 and is expected to reach USD 30,235 million by 2026, with a CAGR of 8.2% during the forecast period. High energy density rechargeable batteries are widely used in portable devices and offer higher efficiency and longer lifespans over other batteries such as lead-acid ones. Among all batteries, Li-ion is one of the lightest rechargeable battery technologies in the market with the highest specific energy and energy density, owing to its high rate of recycling with a low CO2 hydrometallurgical recycling process.

The rapid adoption of electric and hybrid vehicles and renewable energy storage systems has dramatically fuelled the demand for Li-ion batteries that are highly versatile, scalable, and can be adapted to any voltage as per the power and energy requirement. Furthermore, Li-ion batteries are used as an alternative to nickel-metal batteries in electric vehicles, due to their small size and lightweight. According to Bloomberg New Energy Finance, the price of lithium-ion batteries dropped from USD 1000/kWh in 2010 to USD 273/kWh in 2016, and it is further expected to fall to as little as USD 73/kWh by 2030.

Medical Segment by Application to Witness the Most Significant Growth

The medical segment by application was valued at USD 3,316 million in 2018 and is expected to reach a value of USD 6,212 million by 2026, with a CAGR of 8.2% during the forecast period. Medical devices require battery packs for unique power requirements such as in assemblies for healthcare devices, including blood glucose monitors, life-saving devices (surgical tools and respirators), and most other battery-powered medical equipment. Battery packs provide primary or backup power in hospitals that utilize electronic devices for medical care. Moreover, custom medical battery packs are also extensively used in ultrasound devices, drug delivery systems, patient monitors, imaging systems, ventilators, surgical tools, defibrillators, and motorized wheelchairs, among others.

The extensive use of different medical devices and equipment is expected to boost the growth of the custom battery pack market. As per the India Brand Equity Foundation, India’s healthcare industry is one of the fastest-growing sectors and leading destinations for high-end medical devices, equipment, and diagnostic services.

North America Leads the Global Custom Battery Pack Market

North America’s custom battery pack market was valued at USD 9,110 million in 2018 and is expected to reach a value of USD 15,503.5 million by 2026, with a CAGR of 6.9% during the forecast period. The battery storage system market has been witnessing significant growth in the past few years, with vast scope in various applications – from tiny electronic devices to huge military instruments. Lithium-ion batteries largely drive market growth by battery type, with massive investments and efforts by manufacturers to improve the design and build of customized battery packs.

Such developments are being galvanized by more supportive markets and governance, reconstructing battery pack costs, growing approach towards financing, and upgrading infrastructure requirements. BREN-TRONICS, INC., a U.S.-based repackaging private company, is providing the U.S. military custom battery packs for their communication equipment. The company specializes in custom design batteries, and the U.S. military accounts for around 90% of the company’s sales.

Rapid Uptake of EVs & Focus on Reducing CO2 Emission Drive Growth of Europe’s Custom Battery Pack Market

The Europe market was valued at USD 7,206.9 million in 2018 and is expected to reach a value of USD 11,625.4 million by 2026, with a CAGR of 6.2% during the forecast period. Currently, lithium-ion batteries are one of the most expeditiously growing forms of technology in the battery market since they meet specific demands from the rapidly developing electric mobility market. The European Union is aiming to reduce CO2 emissions in the transport sector. As per a European Environment Agency (EEA) report, around 149.5 thousand electric vehicles were sold in the region in 2015.

Custom Battery Pack Market: Market Participants

  • Elecsys France
  • SAFT
  • BMZ Group
  • GPBM Industry
  • Excell Battery Co.
  • PowerTech Systems
  • E4V (Group Universe VE)
  • PMBL Ltd
  • Cadex Electronics Inc.
  • Battery Clinic Inc.
  • Zeus Battery Products
  • Inventus Power
  • Ultralife Corporation

Custom Battery Pack Market: Suppliers

  • Avnet Inc.
  • AceOn Battery Solar Technology Ltd
  • Arrow Electronics, Inc.
  • CAB Special Batteries Ltd
  • Lithium-ion Battery Packs and Cells

Custom Battery Pack Market Segmentation

By Type

  • Li-Ion
  • Li-Poly
  • NiMH
  • NiCd
  • SLA

By Application

  • Medical
  • Military
  • Aerospace
  • Data Center
  • Portable devices
    • Laptops
    • Mobile Phones
    • Point of Sale Devices
    • Audio Devices (Speakers)
    • Power Tools
    • Others
  • Automotive
  • Others

By Region

North America

  • The U.S.
  • Canada
  • Mexico


  • Germany
  • France
  • Italy
  • The U.K.
  • Spain
  • Russia
  • Poland
  • Rest of Europe


  • China
  • India
  • Japan
  • South Korea
  • Australia
  • Vietnam
  • Indonesia
  • Malaysia
  • Singapore
  • The Rest of APAC

Latin America

  • Brazil
  • Argentina
  • Colombia
  • The Rest of Latin America


  • Saudi Arabia
  • The UAE
  • Iran
  • Kuwait
  • Tanzania
  • South Africa
  • The Rest of MEA

Frequently Asked Questions (FAQs)

Li-Ion Segment is expected to be the leading segment in Custom Battery Pack Market during the forecast period.
North America is expected to hold the highest market share in Custom Battery Pack Market.
Elecsys France, SAFT, BMZ Group, GPBM Industry, Excell Battery Co., PowerTech Systems are the top players in Custom Battery Pack Market.
The growing popularity of EVs, the rapid adoption of electric and hybrid vehicles and renewable energy storage systems are the key factors expected to drive Custom Battery Pack Market during forecast period.
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