Feature: Batteries
operation is put to the test under intense usage conditions and directly impacts productivity and safety. While a custom battery design gives the OEM full control and
flexibility over the performance of their product, this route may present additional challenges, particularly around compliance and manufacturing costs. Regulations governing battery safety, transport and recyclability are becoming more complex and OEMs must ensure their products meet customer expectations as well as international regulatory requirements. Despite these challenges, transitioning to a proprietary battery
pack doesn’t need to be a costly or complex exercise. By partnering with a custom battery manufacturer, OEMs can develop high- performance, cost-effective solutions that comply with industry regulations while being precisely optimised for market viability and long-term reliability.
Selecting the right battery technology for power tools When designing battery-powered tools, OEMs must carefully evaluate the advantages and trade-offs of different cell formats when specifying the battery pack. Cylindrical cells remain the industry standard due to their robustness, high discharge rates, and mechanical durability, making them a reliable choice for both consumer and professional-grade tools. Tey are also easy to manufacture at scale, providing consistent performance and cost-efficiency for power tools that require high power output and resilience to impact and vibration. For applications where compactness, weight reduction, and heat
and durability are critical. A customised battery design can be the difference between reliability and failure. In one example, a manufacturer of high-torque tools used on oil rigs and in wind turbine maintenance was experiencing unacceptable failure rates due to harsh operating conditions, including frequent battery damage when the heavy tool was dropped. By integrating a data logging feature within the battery management system, along with an accelerometer to detect drops, Alexander Battery Technologies developed a solution that disables the battery if it is dropped from a significant height. Tis added layer of protection helps prevent accidents and unnecessary returns, making the tools safer and more reliable for the end user.
One size doesn’t fit all and the shift towards custom battery solutions As OEMs strive to differentiate their power tools, there’s a growing trend towards custom battery solutions. Standardised platforms like the Cordless Alliance System (CAS) are a practical choice for some companies providing an easy, cost-effective solution by offering a shared battery platform across multiple tools. However, this approach doesn’t allow for the flexibility and performance optimisation that many tools require, especially for use in industrial and heavy-duty applications. Bespoke battery management systems enable OEMs to tailor
power output, extend run times and add advanced functionality that standardised packs cannot provide. For instance, some tool batteries now feature Bluetooth connectivity, data logging and enhanced thermal protection, all designed to improve performance under demanding environments. Tese features are especially important for categories of power tools where battery
28 April 2025
www.electronicsworld.co.uk
dissipation are critical, some manufacturers are exploring pouch cells. Tese can offer higher energy density in a smaller footprint and, in some cases, support faster charging times. However, pouch cells lack structural rigidity, making them more susceptible to damage and requiring additional packaging to ensure durability in real-world use. Tis adds complexity to battery pack design, particularly for tools that experience high-impact use or extreme conditions. For this reason, cylindrical cells remain the preferred choice for battery design engineers seeking long-term reliability and user safety in power tools.
Navigating regulatory compliance and shipping restrictions One of the most significant concerns for OEMS when exploring the option for a custom battery design is meeting global shipping and safety regulations. Power tool manufacturers must carefully navigate these regulatory frameworks, especially when selling internationally. Batteries exceeding 100 watt-hours are classified as dangerous goods, requiring special packaging, labelling and certifications. In addition, some regions impose certifications, such as UL or CE, making compliance an important consideration in product development and distribution. As battery capacities increase, it’s also important to consider
the environmental impact and recyclability of batteries. Tere’s increasing pressure on manufacturers to develop batteries that can be recycled more efficiently and are less reliant on finite materials like lithium and cobalt. With growing pressure on the industry to meet sustainability goals, power tool manufacturers must design battery packs with recyclability in mind and explore second-life strategies to reduce environmental impact.
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