Custom PACK manufacturing path: cell sorting and matching, structural insulation, controlled assembly, BMS and harness integration, voltage-balance testing, and shipment documentation. Quality-control evidence belongs on the quality page.
PACK manufacturing process
How each custom pack is controlled for consistency, structure, heat input, and delivery condition before sampling or production.
Covers incoming inspection, voltage / IR testing, and coded cell matching.
Cells are screened by voltage and internal resistance per project process rules to reduce the risk of single-cell overheating, voltage sag, and early degradation under high discharge.
Controls PACK consistency at the source
Covers tab trimming, tape fixing, and barley-paper insulation.
For vibration, impact, and high-current duty cycles—including UAV and industrial equipment examples—structure fixing and insulation protection improve mechanical stability and electrical safety.
Anti-vibration insulation for high-current duty cycles
Covers adapter board, tab, power lead, and balance lead soldering.
High-rate pouch cells are sensitive to heat input. Typical high-rate pouch routes control soldering temperature windows and single-point contact time per project process rules to reduce heat transfer into the cell.
Controlled soldering per project process rules
Covers residue inspection, secondary insulation, voltage-balance testing, and shipment.
Before shipment, packs are checked for appearance, insulation, protection, and voltage balance against the project's delivery thresholds.
Delivery-state check against project thresholds
High-rate and UAV value
Drone battery packs are sensitive to cell consistency, tab soldering, insulation, and voltage balance during climb, payload changes, and high-current output. Process control reduces the risk of single-cell overheating, voltage sag, weak solder joints, and vibration-related failure.
View UAV battery packsReduces the risk of voltage sag, heat rise, and capacity deviation under high discharge.
Tape fixing, barley paper, and insulation layers help the pack tolerate flight vibration and assembly shock.
Temperature and contact-time control reduce heat transfer into pouch cells.
Manufacturing integration scope
Receive pouch, polymer, 18650, 21700, 32700, or project-specified cells against the approved specification.
Transfer the approved series-parallel layout, current path, insulation, and mechanical drawing into controlled production.
Assemble the protection PCB, smart BMS, NTC, SOC, CAN, RS485, or SMBus against the approved interface.
XT60, XT90, AS150, balance leads, power harnesses, and custom terminals.
Enclosure, fixing points, tape, barley paper, buffer layers, vibration protection, and service access.
UN38.3, MSDS, shipment labels, model labels, and target-market documentation planning.
Inspection and delivery
Manufacturing process FAQ
Manufacturing focuses on incoming inspection, matching, insulation, assembly, BMS integration, testing, traceability, and document control. Custom design covers undefined cell selection, series-parallel layout, BMS, enclosure, prototype, and production development.
No. Document status depends on the exact cells, PACK configuration, target market, and shipping method and must be confirmed during project review before prototyping or delivery.
Depending on the approved specification, checks can cover incoming appearance, OCV and IR, cell coding and matching, polarity, insulation, welds, mechanical fixing, BMS function, communication, charge-discharge, aging, labels, packing, and traceability.
Next sourcing path
Use these fields to scope process and quality requirements, then continue to custom development or controlled assembly by design maturity.
Inspection gates, matching records, traceability fields, and transport / certification planning belong on the quality page.
Open quality page →When cell selection, series-parallel layout, BMS, enclosure, or validation path is still open, start full engineering design and prototype review.
Open Custom OEM →When cells and architecture are defined, controlled matching, welding, BMS, harness, enclosure, and final validation are available.
Open assembly service →Organize requirements with the full RFQ field list, then submit a design or assembly inquiry by project stage.
Open RFQ checklist →Global delivery and project documentation
Staricell plans cell supply, pack engineering, BMS integration, test records, and shipment documents around each shipping country, application duty cycle, certification target, and production schedule.
Cell supply, pack engineering, BMS integration, production testing, and export documents are planned around each buyer's shipping country, application, and volume schedule.
Project files can cover UN38.3, MSDS / SDS, shipment labels, test summaries, and documentation paths for CE, IEC, UL, RoHS / REACH, and other requirements.
Operating temperature, continuous / peak current, enclosure protection, connectors, chargers, communication interfaces, and field-service needs are reviewed before mass production.
Cell batch data, matching records, BMS settings, inspection results, and aging summaries can be aligned before sampling or pilot production.
