Custom Solutions
Connector, Wire & PCM/BMS Customization
The interface and protection of your battery decide how well it fits, charges, and survives in the field. We match connector, wire layout, and PCM/BMS protection to your exact product — verified on samples before mass production.
What we customize
Three things that make a battery fit your product
Most custom battery problems come down to the interface — not the cell. These are the three areas we tune for every project.
01 · Connector
The right connector
JST, Molex, or a custom terminal — matched to your board, current, mating cycles, and available space.
02 · Wire
Wire built to layout
Gauge, length, polarity, and exit direction set so the pack drops into your enclosure without strain or rework.
03 · Protection
PCM / BMS protection
Over-charge, over-discharge, over-current, and short-circuit protection — sized to your voltage and cell count.
Connector
Connector options we work with every day
Send us a part number, a photo, or your mating connector — we'll confirm fit and polarity before sampling. Common families below.
| Connector | Typical use | Notes |
|---|---|---|
| JST SH (1.0mm) | Ultra-compact wearables, IoT, sensors | Smallest pitch; for low current and tight space |
| JST PH (2.0mm) | 3C devices, small LiPo packs | The most common LiPo connector |
| JST XH (2.5mm) | Larger packs, balance leads | Higher current; common for multi-cell balancing |
| Molex | Industrial & medical devices | Many series — specify the exact one or send a sample |
| Bare tinned leads | Solder-to-board or in-house assembly | No connector; strip length and tinning to spec |
| Custom terminal | Non-standard or proprietary interfaces | Share a drawing or sample and we'll source or tool it |
Wire
Wire that matches your layout, not the other way around
Wire that's too thin overheats; too thick won't route. Too long adds resistance and clutter; too short forces strain on the joints. We set every detail to your enclosure.
- Gauge (AWG) chosen for working current and flexibility
- Length measured from cell tab to connector for your layout
- Polarity & color marked clearly to avoid assembly errors
- Exit direction and routing to fit your housing
- Insulation & sleeving for abrasion and temperature needs
Protection
PCM or BMS — which protection your pack needs
Both protect the cell. The difference is cell count and whether you need balancing. Not sure which applies? We'll advise from your voltage and capacity.
PCM
Protection Circuit Module — single-cell & low-cell packs
- Over-charge protection
- Over-discharge protection
- Over-current & short-circuit protection
- Compact — fits thin LiPo and small packs
- Best for 1S and simple low-cell designs
BMS
Battery Management System — multi-cell packs
- All PCM protections, plus:
- Cell balancing across the series string
- Temperature monitoring options
- Optional fuel-gauge / communication (per project)
- Best for 2S and above — 18650 / 21700 / Li-ion packs
How it works
From your spec to a verified sample
STEP 01
Send requirements
Connector, wire, protection, voltage, capacity, and application — or use the builder below.
STEP 02
Engineering review
We confirm fit, polarity, current, and the right PCM/BMS before anything is built.
STEP 03
Sample & verify
A sample confirms connector position, charging, and assembly fit. No MOQ for samples.
STEP 04
Production supply
After sign-off we follow QC, documents (UN38.3 / MSDS), and stable long-term supply.
Spec Builder
Configure your connector, wire & protection
Pick the options that match your product. We build a clean spec summary as you go — copy it, or send it straight to our engineers for a fast, accurate quote.
Have a connector, wire, or protection challenge?
Send your battery type, connector, wire layout, and protection needs. Our engineers will review a practical, sample-verified solution.
Talk to a Battery Engineer →