Custom Battery Pack Global Market Report 2025

The custom battery pack market size has grown strongly in recent years. It will grow from $21.44 billion in 2024 to $23.07 billion in 2025 at a compound annual growth rate (CAGR) of 7.6%. The growth in the historic period can be attributed to increasing demand for portable electronic devices, increasing adoption of electric vehicles (EVs), rising popularity of battery-powered industrial automation systems, rising use of energy storage systems, and rising cost-effectiveness of lithium-ion batteries.

The custom battery pack market size is expected to see strong growth in the next few years. It will grow to $31.98 billion in 2029 at a compound annual growth rate (CAGR) of 8.5%. The growth in the forecast period can be attributed to Increasing adoption of renewable energy, rise in demand for energy-efficient batteries, rise in hybrid and plug-in hybrid vehicle sales, growth in electric aviation projects, and growth in electrification of public transportation. Major trends in the forecast period include technological advancements, 3D-printed battery components, shift toward non-lithium batteries, 5G and IoT-optimized batteries, and localization of battery manufacturing.

The forecast of 8.5% growth over the next five years reflects a modest reduction of 0.5% from the previous estimate for this market. This reduction is primarily due to the impact of tariffs between the US and other countries. This is likely to directly affect the US through delays in specialized battery management systems (BMS), mainly produced in China and Taiwan, disrupting custom power solutions for medical and military applications. The effect will also be felt more widely due to reciprocal tariffs and the negative effect on the global economy and trade due to increased trade tensions and restrictions.

The increasing adoption of electric vehicles (EVs) is expected to drive the growth of the custom battery pack market. EVs, which rely on electric motors and batteries instead of traditional internal combustion engines, are gaining popularity due to government incentives that reduce purchase costs and promote sustainability through tax credits, subsidies, and infrastructure development. Custom battery packs enhance EVs by optimizing energy storage, improving efficiency, and extending range through tailored designs that meet specific power and performance needs. For example, in April 2024, the International Energy Agency (IEA), a France-based intergovernmental organization, reported that global electric car sales approached 14 million in 2023, accounting for 18% of total car sales, up from 14% in 2022. As a result, the growing adoption of EVs is significantly boosting the demand for custom battery packs.

Key players in the custom battery pack market are focusing on innovative solutions such as structural battery packs to improve energy density, thermal management, and reduce weight, resulting in more efficient and longer-lasting battery solutions. Structural battery packs serve as both energy storage and load-bearing components in a vehicle, eliminating the need for separate battery enclosures and reducing overall weight. These packs enhance vehicle efficiency, structural integrity, and space optimization, making them a vital innovation in EV design. For instance, in May 2023, Williams Advanced Engineering Limited, a UK-based technology firm, introduced Cell2Pack, a solution designed for low-volume EV production. This innovation enhances vehicle stiffness, reduces weight, and extends range by integrating battery cells directly into the pack, eliminating individual modules. Featuring large-format cylindrical cells, inflatable side cooling, and a scalable bent extruded case, Cell2Pack is optimized for niche automotive applications.

In December 2023, Komatsu Ltd., a Japan-based manufacturer of mining, forestry, and industrial heavy equipment, acquired American Battery Solutions Inc. for an undisclosed amount. This acquisition aims to enhance Komatsu’s battery-operated equipment capabilities and further its sustainability goals in the construction and mining sectors. American Battery Solutions Inc., based in the US, specializes in designing and manufacturing lithium-ion battery packs and custom solutions for commercial and industrial applications.

Custom battery packs are energy storage solutions specifically designed to meet unique power, size, and performance needs. These packs are built using various chemistries, configurations, and safety features to ensure optimal efficiency and reliability. They undergo extensive testing and customization to suit specific operational requirements.

The main types of custom battery packs include lithium-ion (Li-ion), lithium-polymer (Li-poly), nickel-metal hydride (NiMH), nickel-cadmium (NiCd), sealed lead acid (SLA), and other types. Lithium-ion batteries are rechargeable energy storage devices that use lithium ions, offering high energy density, long cycle life, and low self-discharge rates. The voltage range of these batteries can be low, medium, or high. These batteries are used in a wide range of applications, such as electric vehicles (EVs), portable power tools, uninterruptible power supplies (UPS), renewable energy storage, and medical devices. They serve various end-users, including those in consumer electronics, automotive, healthcare, energy storage systems, and telecommunications.

Note that the outlook for this market is being affected by rapid changes in trade relations and tariffs globally. The report will be updated prior to delivery to reflect the latest status, including revised forecasts and quantified impact analysis. The report’s Recommendations and Conclusions sections will be updated to give strategies for entities dealing with the fast-moving international environment.

The sharp escalation of U.S. tariffs and resulting trade tensions in spring 2025 are significantly affecting the electrical and electronics sector. Key components such as semiconductors, display panels, and rare-earth metals crucial for batteries and motors are now facing heavy duties. Consumer electronics companies are seeing profit margins shrink, as fierce competition makes it difficult to pass on rising costs to consumers. At the same time, industrial electronics firms are experiencing project delays due to shortages of tariff-impacted parts like printed circuit boards. In response, businesses are shifting assembly operations to tariff-exempt nations, building up inventory reserves, and redesigning products to reduce reliance on restricted materials.

The custom battery packs market research report is one of a series of new reports that provides custom battery packs market statistics, including the custom battery packs industry global market size, regional shares, competitors with the custom battery packs market share, detailed custom battery packs market segments, market trends, and opportunities, and any further data you may need to thrive in the custom battery packs industry. This custom battery packs market research report delivers a complete perspective of everything you need, with an in-depth analysis of the current and future scenarios of the industry.

Major players in the custom battery pack market are Grepow Battery Co. Ltd., Alpha Source Inc., Evolute Group LLC, Epec Engineered Technologies Inc., Zeus Battery Products Inc., Enix Power Solutions LLC, EPT Battery Co. Ltd., Excell Battery Co. Inc., Southwest Electronic Energy Group Inc., Alexander Battery Technologies Inc., Tritek Solutions Inc., Rapport Inc., Emerging Power Inc., Godson Technology Co. Ltd., Cell Pack Solutions GmbH, AceOn Group Ltd., Custom Power Inc., Robu.in, Rose Batteries Inc., TTekAI Inc., Voltaplex Technologies Inc., and CM Batteries Inc.

North America was the largest region in the custom battery pack market in 2024. The regions covered in custom battery pack report are Asia-Pacific, Western Europe, Eastern Europe, North America, South America, Middle East and Africa.

The countries covered in the custom battery pack market report are Australia, Brazil, China, France, Germany, India, Indonesia, Japan, Russia, South Korea, UK, USA, Canada, Italy, Spain.

The custom battery pack market consists of sales of lead-acid battery packs, high-performance battery packs, wearable battery packs, industrial battery packs, and custom-designed battery modules. Values in this market are ‘factory gate’ values, that is, the value of goods sold by the manufacturers or creators of the goods, whether to other entities (including downstream manufacturers, wholesalers, distributors, and retailers) or directly to end customers. The value of goods in this market includes related services sold by the creators of the goods.

The market value is defined as the revenues that enterprises gain from the sale of goods and/or services within the specified market and geography through sales, grants, or donations in terms of the currency (in USD, unless otherwise specified).

The revenues for a specified geography are consumption values that are revenues generated by organizations in the specified geography within the market, irrespective of where they are produced. It does not include revenues from resales along the supply chain, either further along the supply chain or as part of other products.

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