We do not recommend custom casing for the first sample run. Rather, we recommend you only producing custom casing for mass production runs because of the additional cost. Custom cases require custom molds, with a custom casing mold cost typically ranging from USD $5,000 and $20,000 depending on size, IP level, and other.

There are not necessarily standard sizes, since the variety of battery packs is so great. For example 3.7V, 7.4V, 12V, 100V, and so on may all have different casing requirements. Lithium polymer cells most often have custom sizing. Cylindrical cells like 18650, 21700, etc. may be more standardized than Lipo however the PCB, assembly, accessories, and so on almost always change and thus the housing space changes.

There are some pack casing like 12V or 24V series for E-bike for example which can be used in some cases. However we seldom consider them because soldering requirements, and that the size is usually a bit too small or a bit too large to fit the custom battery packs we produce.

For opening a new mould there are two material options we typically use. One is plastic and the other steel.

Plastic tooling price

This is generally expensive, and mostly depends on the housing complexity and framework, the number of moulds, and the materials of the housing (ABS, PC, etc.)

For plastic we normally require the following details before we can make an evaluation:

Steel tooling price

Steel cases are easier and have less cost compared to plastic cases. However mostly these are used for larger packs for example 24V, 100Ah, or 48V, 50Ah, or 100V, 300Ah.

For steel casing customers do not need to provide much documentation. The estimated cost per steel case is roughly 30 USD to 120 USD depending on factors like ingress protection rating (for example if it needs to exceed IP54).