We build custom LiFePO4 packs from 12 V through 96 V systems, sized from your discharge profile rather than picked off a catalogue.
LFP is our most-specified chemistry for anything cycled hard: energy storage and solar, marine and RV, AGV and industrial robotics, telecom backup. CAN and RS485 BMS communication is standard; MOQ and lead time follow our standard tiers.
New to the chemistry? Start with what LiFePO4 batteries are, and their limitations. This page assumes you have already chosen LFP and covers what we need in order to build it.
Configurations we build
| System voltage | Series count | Charge / cut-off window | Common applications |
|---|---|---|---|
| 12 V | 4S | 14.6 V charge / 10.0 V cut-off | RV and marine house banks, trolling motors, portable power |
| 24 V | 8S | 29.2 V / 20.0 V | AGV, floor-care machines, telecom, small off-grid |
| 36 V | 12S | 43.8 V / 30.0 V | Light electric vehicles, industrial tools |
| 48 V / 51.2 V | 16S | 58.4 V / 40.0 V | Rack and wall-mount storage, inverter-coupled systems, robotics |
| 72 V | 24S | 87.6 V / 60.0 V | Industrial vehicles, forklifts, specialty EVs |
| 96 V | 30S | 109.5 V / 75.0 V | Larger storage systems, heavy industrial vehicles |
Figures above are nominal 3.65 V charge / 2.5 V cut-off per cell and get tuned to your duty cycle — a pack that sits at float most of its life wants different thresholds from one that is cycled to empty daily. Parallel count and cell format follow from your usable-energy figure and physical envelope. Higher voltages on request. For voltage-to-state-of-charge behaviour, see our LiFePO4 voltage chart.
BMS specification, per project
The BMS is where most LFP packs succeed or fail in the field, and it is specified per project rather than bolted on. We set continuous and peak discharge limits, charge current, cut-off thresholds, balancing behaviour and temperature protection windows against your actual load.
CAN and RS485 are standard, covering inverters, charge controllers and vehicle buses — same platform described on our BMS and communication page. Bluetooth is the usual choice for local state-of-charge monitoring; 4G and GPS are project-specific customisations, not stock features.
Two decisions worth making deliberately rather than by default:
- Passive or active balancing. Passive is right for most packs. Active earns its cost in applications with frequent partial charging — solar, regenerative braking. We set out when it actually pays in active vs passive balancing on LFP and high-voltage packs.
- Which protocol, and whose dialect of it. CAN is not one thing; your inverter expects a specific message set. Send that device’s protocol document with your enquiry — it is the detail most often missing from first-round specs, and it decides whether the pack works on day one. Background: battery communication protocol options.
Cold weather, and being straight about it
Charging in the cold is the real constraint
LiFePO4 discharges fine in the cold. Charging is the constraint — standard cells should not be charged below 0 °C, and that is a cell-chemistry limit, not something a better BMS solves. The options are low-temperature-grade cells that accept slow charging down to around −20 °C, a heated pack, or a charge-inhibit threshold that simply blocks charging until the pack warms up.
Heating pads are not automatically the answer, and we have written about a case where we removed them. Tell us the actual minimum temperature at which the pack must accept charge — not the storage minimum — and we will tell you which of the three routes fits.
Warranty and what shortens it
We typically write 3–5 years on LiFePO4 packs — see the full warranty table on Battery Pack Manufacturing → A pack built for high continuous discharge carries a shorter term, because sustained high current is what consumes cell life. The figure that applies to your build goes into the quotation rather than staying a marketing claim.
Cells, documentation and lead time
Grade A cells, sourced the same way described on our Battery Pack Manufacturing page. Every pack ships with a UN38.3 test report and an MSDS. Lead time follows our standard sample and production tiers on the same page — cell procurement is the usual constraint, so give us your target date up front and we check live stock against it.
What to send us
- System voltage and usable capacity (Ah or Wh).
- Continuous discharge current, plus peak current and how long the peak lasts.
- Charging source — charger, solar controller or alternator, and its profile.
- Maximum enclosure dimensions, weight budget, mounting and IP requirement.
- The protocol document for whatever the pack must communicate with.
- Real minimum and maximum operating temperature, and the minimum charging temperature.
- Target date and intended annual volume.
Replacing an existing battery? A photo of it and its connector communicates more than a spreadsheet.
Frequently asked questions
Can you build a drop-in LiFePO4 replacement for a lead-acid bank?
Usually — it is a common 12 V and 24 V request. Send the physical dimensions of the existing battery, the terminal type and position, and the charging source. The charger or alternator profile matters as much as the box dimensions, because many lead-acid chargers use a profile that will not fully charge an LFP pack.
How many cycles will a LiFePO4 pack last?
Cycle life depends on depth of discharge, discharge rate and temperature far more than on any headline number from a cell datasheet. Send your duty cycle and we will give you an expected service life for that use.
Will the pack work with my existing inverter?
In most cases yes, via CAN or RS485. Send the inverter model and its protocol document and we confirm before quoting rather than after delivery.
Is 48 V the same as 51.2 V?
Yes — both describe a 16S LFP pack. 51.2 V is the arithmetically correct nominal (16 × 3.2 V); 48 V is the legacy convention inherited from lead-acid. Equipment listed for 48 V lithium is expecting the same pack.
Is there a minimum order?
Same tiers as our general capability — no MOQ, 100+, or 300–500, depending on tooling and BMS firmware. Full breakdown on Battery Pack Manufacturing →
How a custom pack gets engineered, phase by phase → · Battery Pack Manufacturing →
Send Us A Spec
Get a buildable LFP proposal, not a catalogue link
System voltage, usable capacity, discharge profile, enclosure limits, communication protocol and your target date. That is enough to start a real quotation.