Custom Battery Engineering & Manufacturing

Custom Lithium Battery Systems for OEM & Industrial Applications

Bonnen Battery engineers LFP, NMC and sodium-ion battery systems around your voltage, power, runtime, installation space, communication and operating environment—from prototype development to production.

Discuss Your Battery Project Explore Battery Solutions
Custom platforms · multiple chemistries · system-level integration
Bonnen technicians assembling multiple custom battery packs on the production floor
  • LFP, NMC & Sodium-ion
  • Custom BMS & CAN
  • IP65 / IP67 Options
  • Air & Liquid Cooling
  • Prototype to Production

Core Applications

Battery Systems Built Around the Application

Start with the equipment, duty cycle and installation constraints. Each application path focuses on the engineering decisions that shape the final battery system.

Conceptual electric-workboat application scene based on the supplied Bonnen marine battery reference

01 / MARINE

Marine Battery Systems

Propulsion and onboard-energy systems developed around vessel space, motor demand, charging and marine exposure.

  • Propulsion load
  • Space & mounting
  • Environmental protection
Explore Marine Battery Systems
Conceptual electric commercial-vehicle integration scene based on the supplied Bonnen EV battery reference

02 / ELECTRIC VEHICLE

Electric Vehicle Battery Systems

Custom packs matched to vehicle voltage, peak and continuous power, packaging, communication and charging architecture.

  • Power profile
  • Vehicle CAN
  • Thermal strategy
Explore EV Battery Systems
Conceptual underground-mining application scene based on Bonnen heavy-equipment module-3

03 / HEAVY EQUIPMENT

Heavy Equipment Battery Systems

Rugged battery architectures evaluated against harsh duty cycles, vibration, thermal loads and service access.

  • Peak demand
  • Rugged enclosure
  • Cooling integration
Explore Heavy Equipment Batteries
Conceptual commercial energy facility scene based on the supplied Bonnen C and I storage cabinet reference

04 / C&I ENERGY STORAGE

Commercial & Industrial Energy Storage

Cabinet and system configurations reviewed around site loads, power conversion, thermal management and deployment requirements.

  • Load profile
  • PCS & EMS interface
  • Thermal management
Explore C&I Energy Storage
Conceptual automated-warehouse scene based on the supplied Bonnen AMR and AGV battery module reference

05 / MOBILE ROBOTICS

AMR & AGV Battery Systems

Battery modules designed around robot duty cycle, charging windows, available volume and host communication.

  • Duty cycle
  • Opportunity charging
  • CAN integration
Explore AMR & AGV Batteries
Conceptual refrigerated-transport scene based on the supplied Bonnen TRU battery reference

06 / COLD CHAIN

Transport Refrigeration Unit Battery Systems

Battery and integrated-power systems configured around refrigeration demand, route profile, regional output and chassis space.

  • Startup load
  • Under-chassis space
  • AC / DC interface
Explore TRU Battery Systems

Application-First Development

Engineered Around Your Platform—not a Standard Box

The battery architecture is defined by how the machine works, where the system fits and how it must connect, charge and operate.

01

Your Requirements

  • Motor or load power
  • Voltage and current
  • Runtime and duty cycle
  • Installation space
  • Communication
  • Operating environment
02

Bonnen Battery Engineering

  • Cell chemistry and configuration
  • BMS and HV architecture
  • Enclosure and mounting
  • Cooling or heating
  • Charging and interfaces
  • Safety and protection
03

Project Output

  • Technical proposal
  • Electrical specification
  • Mechanical drawing
  • Prototype
  • Validation plan
  • Production documentation

You do not need a complete battery specification to start. Share what you already know, and our engineers can help define the remaining requirements.

Discuss Your Battery Project
Conceptual engineering prototype showing Bonnen heavy-equipment modules integrated with protected power, control and cooling hardware

System-Level Integration

Battery Engineering Beyond Voltage and Capacity

Electrical, mechanical, thermal and communication decisions are developed together around the host platform.

Electrical Architecture

Define voltage, current paths, switching, protection and power distribution around the load and charging system.

Cell Chemistry & Configuration

Evaluate LFP, NMC or sodium-ion options and series-parallel configuration against energy, power, space and environment.

BMS & Vehicle Communication

Develop monitoring, protection, control logic and CAN communication for the battery and host equipment.

Mechanical Packaging & Mounting

Coordinate enclosure geometry, mounting interfaces, service access, connector placement and structural requirements.

Thermal Management

Select passive, air, liquid, heating or combined approaches according to duty cycle and operating conditions.

HV Safety, Charging & Power Conversion

Integrate project-appropriate isolation, interlock, pre-charge, charging and conversion interfaces.

Published Reference Systems

Reference Platforms, Customized for the Final Application

These published systems illustrate different voltage, energy and integration levels. They are starting references—not fixed specifications for every project.

Conceptual factory inspection visualization of a dual-pack marine reference platform

Marine

96V / 102V Catamaran Battery System

42 kWh published reference

  • Dual-pack architecture
  • Marine enclosure integration
  • Custom system interfaces

Reference configuration. Final specifications are defined around the project.

View Marine Reference
Conceptual factory inspection visualization based on Bonnen heavy-equipment module-3

Heavy Equipment

600V Electric Tractor Battery Pack

100 kWh published reference

  • High-voltage architecture
  • Compact machinery packaging
  • Powertrain integration

Reference configuration. Final specifications are defined around the project.

View Equipment Reference
Conceptual factory inspection visualization of a Bonnen C and I energy-storage reference cabinet

C&I Energy Storage

Liquid-Cooled Energy Storage System

110KW 225KWH Sodium-Ion published reference

  • Cabinet system design
  • Liquid thermal management
  • Grid and site integration

Reference configuration. Final specifications are defined around the project.

View C&I Reference
Conceptual factory inspection visualization of a Bonnen transport-refrigeration battery reference system

Transport Refrigeration

Integrated TRU Battery System

371.2 VDC / 39 kWh published reference

  • Battery-only or integrated system
  • Under-chassis packaging
  • AC or DC interface review

Reference configuration. Final specifications are defined around the project.

View TRU Reference

Development Path

From Requirements to a Production-Ready Battery System

A staged engineering process keeps platform decisions, interfaces, prototype learning and production documentation connected.

  1. Requirements review icon01

    Requirements Review

    Application, loads, space, environment and project targets.

  2. Battery architecture and sizing icon02

    Battery Architecture & Sizing

    Chemistry, voltage, power and energy concept.

  3. Electrical and mechanical design icon03

    Electrical & Mechanical Design

    BMS, protection, interfaces, enclosure and mounting.

  4. Battery prototype build icon04

    Prototype Build

    Build the agreed configuration for integration work.

  5. Battery validation and refinement icon05

    Validation & Refinement

    Review performance and integration against the plan.

  6. Battery production and delivery icon06

    Production & Delivery

    Controlled manufacturing, documentation and logistics.

Real Project Experience

Battery Integration Across Marine, Mining and Energy Storage

Three mass-production programs show how application requirements are translated into battery architecture, interfaces, protection and production documentation.

Netherlands · Electric Workboat

European Marine OEM

Customer identity protected by NDA

Custom battery system102.4 V / 412 Ah dual-battery system · approximately 42.2 kWh
Integration Challenge
Fit the required energy into limited hull spaces while managing weight distribution, service access, moisture, salt exposure, vibration and restricted ventilation.
Engineering Scope
Coordinated dual-pack architecture, BMS and electrical design, marine enclosure and sealing, cable routing, plus propulsion and charging interfaces.
Mass productionRelated system

Australia · Mining Traction Vehicle

Australian Mining Equipment OEM

Customer identity protected by NDA

Custom high-voltage system627.2 V / 690 Ah · approximately 432.8 kWh
Integration Challenge
Support sustained traction and peak-power events under mining vibration, dust and temperature conditions within defined mounting and service constraints.
Engineering Scope
High-voltage architecture, peak-current paths, thermal and mechanical integration, service access, BMS logic and CAN communication.
Mass productionRelated system

Italy · Commercial & Industrial ESS

Italian C&I ESS OEM

Customer identity protected by NDA

Commercial energy storage100 kWh high-voltage battery storage cabinet
Integration Challenge
Combine 100 kWh of storage with BMS, PCS and EMS interfaces, thermal control and high-voltage protection in a compact, maintainable cabinet.
Engineering Scope
Battery and high-voltage architecture, control-system integration, thermal management, cabinet layout, protection and repeatable production testing.
Mass productionRelated system

Project identities are withheld under NDA. Configuration details shown here are limited to the approved public case information supplied by Bonnen Battery.

Manufacturing Evidence

Built, Tested and Documented for the Project

At Bonnen Battery, we assemble and inspect battery modules and complete packs through controlled production stages. We define the final validation plan around each confirmed configuration.

Bonnen operator working at automated cell grading equipment

Cell Grading & Matching

Incoming cells grouped for consistent module assembly.

Battery module assembly stations inside the Bonnen factory

Module Assembly

Controlled mechanical and electrical build steps.

Bonnen technicians assembling battery packs on the production floor

Pack Assembly

System build around the approved configuration.

Automated laser welding equipment processing battery components

Laser Welding

Automated joining for selected module designs.

Bonnen battery packs connected to electrical function test equipment

Electrical Function Testing

Configuration-specific checks before release.

Technician performing battery enclosure airtightness testing

Enclosure Airtightness Testing

Seal verification according to the project plan.

Configuration-Specific Review

Compliance and Delivery Reviewed for the Final Configuration

Applicable requirements depend on the battery architecture, destination market, transport route and installation. Bonnen Battery can coordinate the review and documentation around the confirmed project.

Transport Documentation Support

Plan transport-related testing and documentation around the final battery configuration.

Destination-Market Review

Identify relevant market, equipment and integration requirements before release.

Project Documentation

Coordinate specifications, drawings, validation records and production documents.

Packaging & Shipping Coordination

Review packaging and logistics needs against the battery system and destination.

Global OEM Project Support

Maintain technical communication across development, prototype, production and delivery.

Engineering Resources

Resources for Battery System Planning

Use these guides to frame duty-cycle, thermal and enclosure questions before a project review.

Sizing & Duty Cycle

How to Size an Underground Mining Truck Battery

Why usable energy, continuous and peak power, route profile and charging windows must be evaluated together.

Read the Sizing Guide

Thermal Management

Liquid Cooling for Battery Energy Storage Systems

An overview of how C&I storage systems manage heat across cells, cooling circuits and operating conditions.

Read the Cooling Guide

Mechanical Integration

Lithium Battery Enclosure Design for EV, Marine & Industrial Systems

How structure, sealing, vibration, corrosion, interfaces and service access influence the battery enclosure.

Read the Enclosure Guide

FAQs About Custom Lithium Battery Systems

You need more than just a single lithium ion battery pack​. You need a veteran manufacturer who has been in the field for 10+ years to save your project time, build your brand and grow your profits. Let Bonnen Battery help you achieve business success.

Bonnen Battery develops custom lithium battery systems for OEM and industrial applications, including electric vehicles, marine propulsion, heavy equipment, commercial and industrial energy storage, AMRs and AGVs, transport refrigeration units, and other electrified machinery. Battery voltage, capacity, power capability, enclosure, BMS, communication, thermal management, and interfaces can be configured around the requirements of the final application.

Yes. You do not need to finalize the battery voltage, capacity, dimensions, or BMS before contacting us. Start by sharing what you already know, such as the application, motor or load power, available installation space, desired runtime, charging method, operating environment, and communication requirements. Our engineering team can then help define the remaining battery system requirements.

The most useful starting information includes your application, nominal system voltage, continuous and peak power or current, required runtime, available installation space, charging method, expected operating temperature, communication protocol, and estimated order quantity. If some information is not yet available, we can still begin the technical discussion and identify what needs to be confirmed during the engineering process.

Yes. Bonnen Battery develops both low-voltage and high-voltage battery architectures for electric vehicles, construction and mining equipment, agricultural machinery, marine systems, and other high-power applications. Depending on the project, the system design can include high-voltage BMS architecture, contactors, pre-charge circuits, fuses, isolation monitoring, CAN communication, thermal management, and other protection and control components.

Yes. Mechanical packaging is an important part of custom battery engineering. We can evaluate the available installation envelope, mounting points, connector positions, service access, weight distribution, sealing requirements, vibration conditions, and cooling needs when developing the enclosure. The objective is to integrate the battery into the equipment rather than force the equipment to fit a standard battery box.

Yes. Custom BMS and CAN communication can be developed around the host vehicle, machine, charger, inverter, motor controller, PCS, or other system components. During the project, communication requirements such as CAN protocol, baud rate, message mapping, operating logic, alarms, SOC information, charging control, and interface requirements can be reviewed with your engineering team.

The best battery chemistry depends on the priorities of the project rather than one chemistry being suitable for every application. LFP is commonly considered when cycle life, thermal stability, and durability are important, while NMC may be evaluated when higher energy density and limited installation space are major priorities. Sodium-ion can also be considered for selected stationary or industrial applications. We evaluate chemistry together with power, energy, space, temperature, weight, lifecycle, and cost requirements before recommending a configuration.

Yes. Battery thermal management can be designed according to the power profile, duty cycle, cell chemistry, installation environment, charging rate, and operating temperature range. Depending on the application, the solution may use passive cooling, forced-air cooling, liquid cooling, battery heating, or a combined thermal-management strategy. High-power EVs, heavy equipment, marine propulsion, and energy storage systems often require a more detailed thermal assessment.

Yes. A custom battery project can progress from requirements review and battery architecture through electrical and mechanical design, prototype development, validation, refinement, and production. Prototype builds allow the battery and host equipment to be evaluated together before the final configuration is released for repeatable manufacturing.

Testing and documentation are defined according to the final battery configuration, application, destination market, and transportation requirements. Bonnen Battery can coordinate project specifications, mechanical drawings, electrical documentation, production and inspection records, battery validation requirements, transport-related documentation, packaging, and shipping preparation. Applicable certification and compliance requirements should be reviewed for each project rather than assumed from a standard battery platform.

Project Inquiry

Start with What You Know

You do not need to finalize the voltage, capacity or enclosure before contacting us. Share your application, motor or load, target runtime, installation space and operating environment, and our team can help define the next engineering steps.

Discuss Your Battery Project