Custom Battery Pack Market Report 2026

The custom battery pack market size has grown strongly in recent years. It will grow from $23.07 billion in 2025 to $25.03 billion in 2026 at a compound annual growth rate (CAGR) of 8.5%. The growth in the historic period can be attributed to growing adoption of portable electronics, demand for reliable energy storage, advancements in lithium-ion chemistry, expansion of electric vehicle market, increased focus on battery safety.

The custom battery pack market size is expected to see strong growth in the next few years. It will grow to $34.7 billion in 2030 at a compound annual growth rate (CAGR) of 8.5%. The growth in the forecast period can be attributed to rising demand for renewable energy integration, growth in autonomous vehicles, increasing need for high-performance batteries, adoption of modular energy storage solutions, development of next-generation battery chemistries. Major trends in the forecast period include high energy density battery design, advanced thermal management solutions, customizable battery form factors, enhanced safety and protection features, modular and scalable battery systems.

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 January 2025, Cox Automotive, a US-based system software company, reported that electric vehicle (EV) sales in 2023 were revised upward to 1,212,758 units, marking a 49% increase compared to 2022, and continued to grow in 2024, rising by 7.3% to reach 1,301,411 units. As a result, the growing adoption of EVs is significantly boosting the demand for custom battery packs.

Leading companies in the custom battery pack market are focusing on developing innovative solutions, such as software-defined architectures and mixed-cell configurations, to provide both high power output and extended energy performance. Software-defined architectures are battery systems managed by intelligent software that regulates performance, safety, and energy consumption, while mixed-cell configurations integrate different types or ages of battery cells within a single pack to optimize power and longevity. For example, in February 2025, Tanktwo Oy, a Finland-based technology company, launched Surge-and-Sustain custom battery packs, engineered to deliver both high surge power and sustained energy for industries including manufacturing, construction, aviation, and military. Utilizing proprietary technology and a software-defined battery system, these packs can combine cells of varying chemistries and ages, optimizing power output without adding unnecessary weight or cost. Key features include the ability to mix diverse cells through software-controlled parameters, enabling equipment manufacturers to create battery packs tailored to specific operational requirements. This approach enhances performance, flexibility, and cost-efficiency across multiple sectors.

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.

Major companies operating 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., CM Batteries Inc.

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.

Tariffs have influenced the custom battery pack market by increasing the cost of importing raw materials and battery components, particularly affecting lithium-ion and lithium-polymer segments. Regions like Asia-Pacific, including China and South Korea, which are major manufacturing hubs, are most impacted due to supply chain disruptions. Automotive and renewable energy storage applications face notable cost pressures, while manufacturers are accelerating local production and diversifying suppliers. Positive impacts include incentivizing domestic manufacturing and fostering innovation in cost-efficient and high-performance battery solutions.

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.

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.North America was the largest region in the custom battery pack market in 2025. The regions covered in the custom battery pack market report are Asia-Pacific, South East Asia, Western Europe, Eastern Europe, North America, South America, Middle East, Africa. The countries covered in the custom battery pack market report are Australia, Brazil, China, France, Germany, India, Indonesia, Japan, Taiwan, 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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