Battery Pack Assembly

Fedco's production department is equipped with all of the necessary tools and equipment required to manufacture a quality, compliant battery pack.  Fedco's skilled assemblers take pride in their work and build in the quality that the customer expects. 

Cell Warehousing:

Fedco only uses battery cells acquired from quality manufactures like Panasonic, Sanyo, FDK (f/k/a Sanyo), Sony, Samsung, JHyPower, Renata, Saft, Ultralife, Varta-Microbattery, Energizer, EnerSys/Cyclon (f/k/a Hawker) and Intec Industries. Lithium-ion cells are factory matched for use in multiple cell packs. Our warehouse is temperature controlled and we make careful note of the supplier's date codes and use them on a first-in first-out basis.


Connecting cells to each other or adding solder tabs or other circuitry to cells is an important step in battery assembly. Soldering directly to cells is not acceptable as the integrity of the cell will be destroyed by the heat. Connections are made using either precision capacitor discharge welders or three-phase high-frequency welders. During welding operations weld strength is verified using a non-destructive pull tester.


Today's lithium-ion technology requires that the battery assembly contains a Protection Circuit Module (PCM) safety circuit to protect each cell in the battery from over-charge, over-discharge, and short circuit. In addition, many battery designs require an electronic interface to communicate battery status to the host device. Fedco utilizes an Electro-Static Discharge (ESD) safe zone that meets the ANSI / ESD S20.20 - 2007 standards to assure the integrity of the circuits used in Fedco's batteries.


Fedco's assembly department uses only lead free solder and is fully RoHS compliant. In addition, only temperature controlled solder stations are used.

Heat shrink tubing:

All Poly Vinyl Chloride (PVC) and Poly Olefin tubing and sleeves are UL listed.

Molded plastic housings:

Many battery packs require custom molded ABS plastic housings. Fedco's molded housing are engineered and made by sub-contractors (many in Wisconsin) for improved continuity of the overall project design. Fedco use a CNC controlled ultrasonic welder for sealing the battery housings that reduces setup time considerably.


In addition to identifying the nominal voltage, rated current and in the case of rechargeable batteries the watt-hour rating, Fedco includes all required agency, chemistry and recycling markings on the printed label. Fedco also has the capability of printing the customer's logo on the label as well as providing hot-stamp marking on molded plastic housings.


Fedco offers a wide variety of packaging solutions, to fully meet your needs. Small batteries up to about 8 ounces are sealed in 4-mil plastic bags. Fedco has the capability of printing the customer's logo, part number and date code on each bag. Larger batteries are individually wrapped in insulated material. Individual boxes and custom shipping cartons, including dividers can be provided to meet any specific need. Fedco strives to assure that your product arrives intact, and as presentable as it is functional.