Premium NMC & LiFePO4 battery pack Assembly with 100% QC Grading

Reliable Lithium Battery Packs

We manufacture a range of modular and custom lithium-ion battery packs for high-demand industries. Whether you need a compact battery for robotics or a scalable solution for energy storage systems, PowerFabb has you covered. 

Battery Cell Types We Work With

Li-ion NMC Cylindrical Battery Cells

Engineered for high energy density and maximum power output in a compact form factor. These cells provide the lightweight burst power required for high-performance EV 2-Wheelers and Drones.

Maximum range and power-to-weight ratio.

LiFePO4 Cylindrical Battery Cells

Delivering exceptional thermal stability and a prolonged cycle life. This robust chemistry is the industry standard for autonomous Robotics, AGVs, and compact UPS systems where long-term safety is critical.

Ultra-safe with thousands of stable charge cycles.

LiFePO4 Prismatic Battery Cells

High-capacity structural blocks designed for heavy-duty, scalable energy storage. The ultimate foundation for large-scale Inverter backups, telecom power, and industrial mobility.

Massive capacity, sustained output, and heavy-duty reliability.

Our Assembly Process

Incoming Material Inspection

Visual and structural inspection of all raw materials upon arrival, ensuring casings, pure nickel strips, wiring harnesses, and raw cells meet strict baseline standards before entering the cleanroom.

Cell IR & Capacity Testing

Randomized batch testing of incoming cells. We conduct deep internal resistance (IR) and true-capacity verification tests to ensure the manufacturer’s spec sheet matches reality.

Cell Grading & Sorting

Every single cell is individually categorized. We sort and group cells with identical voltage, internal resistance, and capacity metrics to guarantee perfect pack balance and prevent premature cell degradation.

Structural Preparation & Insulation

Cells are aligned into rigid structural brackets for maximum vibration resistance. Specialized insulation rings (barley paper/fish paper) are applied to the positive terminals to prevent any risk of short circuits.

Precision Spot Welding

Automated/semi-automated spot welding is used to attach high-conductivity pure nickel strips. This creates permanent, low-resistance connections between cells in series and parallel.

Weld QC & Structural Integrity Check

A thorough manual and instrumented inspection of the weld points. We verify the tensile strength and electrical conductivity of the joints to ensure zero weak spots or potential thermal bottlenecks.

BMS Integration

The Battery Management System (BMS)—the brain of the pack—is carefully soldered and integrated. Balance wires are connected to every parallel group to ensure the BMS can monitor and protect individual cell clusters.

Thermal Management & Wiring

High-grade silicone wiring is routed securely. Heat-shrink tubing, Kapton tape, and thermal conductive pads are applied to manage heat dissipation and isolate high-voltage paths.

Semi-Finished Pack Testing

Before sealing, the exposed pack undergoes a preliminary electrical test. We verify raw voltage output, BMS communication limits, and trigger short-circuit protection to ensure the board responds instantly.

Casing & Sealing

The tested pack is secured inside its final structural casing (custom metal fabrication, ABS plastic, or epoxy board shrink-wrap) to protect against mechanical impact, moisture, and dust.

Final QC & Cycle Testing

The finished product undergoes a rigorous charge and discharge cycle test. We push the pack to its continuous current limits to verify its true usable capacity and thermal stability under real-world load.

Documentation & Dispatch

The pack is cleaned, labeled with strict tracking SKUs and safety warnings, and securely packaged for B2B transport, ready for integration into your EVs or inverters.