B2B BATTERY SYSTEM ENGINEERING

Custom High-Voltage Battery Systems

Engineered around your equipment — not a fixed battery catalog.

LiFirst develops project-based high-voltage lithium battery systems for equipment manufacturers, industrial integrators and professional mobility applications.

Each system is evaluated around voltage, capacity, continuous and peak current, duty cycle, charging architecture, BMS, communication, enclosure, installation space, thermal requirements and operating environment.

VOLTAGE ARCHITECTURE 400V / 800V / Custom
SYSTEM DEVELOPMENT Electrical + Mechanical + Control
PROJECT PATH Prototype to Project Production
For OEMs, equipment manufacturers, engineering integrators and project teams with non-standard power requirements.
PROJECT ARCHITECTURE
HV-SYS / REQUIREMENT REVIEW
Custom high-voltage battery system CAD rendering with enclosure, battery management, high-voltage control and equipment interfaces
PROJECT-SPECIFIC SYSTEM CAD / Mechanical Integration View
INPUT 01 Equipment Type
INPUT 02 Voltage & Current
INPUT 03 Installation Space
INPUT 04 Operating Cycle
ENGINEERED POWER SYSTEMS

Battery architecture is evaluated as part of the complete equipment system.

Diagram showing a custom high-voltage battery system integrated with charging equipment, power converters, motors, pump systems, lifting mechanisms, communication interfaces, and vehicle electrical systems.

Built Around Your Equipment, Not a Fixed Catalog

Engineering review diagram for a custom high-voltage battery system covering electrical architecture, load profile, installation constraints, charging method, communication requirements, and operating environment.

LiFirst’s high-voltage battery systems are developed on a project basis.

We do not expect professional customers to adapt their equipment to a fixed battery pack. Instead, the battery system is evaluated around the equipment’s electrical architecture, load profile, installation constraints, charging method, communication requirements, and operating environment.

Each project begins with an engineering review rather than a standard product selection.

CAD rendering of a custom 460.8V 36Ah high-voltage battery system showing internal control electronics, electrical components, connectors, and enclosure structure.

What Can Be Customized?

A high-voltage battery project is not defined by voltage alone. LiFirst evaluates the battery as an integrated electrical, mechanical, charging, control, and equipment-interface system.

Electrical Configuration

• Voltage platform
• Battery capacity
• Continuous discharge current
• Peak discharge current
• Load and duty-cycle requirements
• Charging voltage and charging method
• Output and protection requirements

Transparent CAD cutaway of a custom 460.8V 36Ah battery system showing the battery modules, upper control compartment, display panel, handles, and mounting structure.

BMS and Communication

• Voltage, current, and temperature monitoring
• Cell balancing strategy
• Fault and protection logic
• CAN, RS485, or other communication requirements where applicable
• Equipment controller integration
• Project-specific BMS parameter configuration

Top-view CAD drawing showing the internal control boards, electrical components, connector placement, and structural layout of a custom 460.8V 36Ah battery system.

Mechanical and Installation Design

• Available installation space
• Battery dimensions
• Enclosure structure
• Mounting method
• Connector selection
• Cable outlet direction
• Vehicle-mounted or equipment-mounted integration
• Shock and vibration considerations

Professional industrial battery system integration block diagram showing external charger, on-board charger, custom high-voltage battery system, BMS and protection, motor controller, electric motor, high-pressure pump, lifting mechanism, and vehicle electrical system. Clean white background, simple engineering icons, clear arrows, minimal text

Charging and Equipment Integration

• On-board or external charging
• Charger matching
• Motor and controller matching
• Pump system integration
• Lifting mechanism integration
• Vehicle electrical system integration

THERMAL MANAGEMENT ENGINEERING

Integrated Thermal Management for High-Voltage Battery Systems

01

For high-voltage battery systems operating under sustained power, frequent cycling, compact installation, or wide ambient temperature ranges, thermal management must be engineered as part of the complete battery architecture — not added after the battery pack has been built.

ENGINEERING EXAMPLE
LIQUID-COOLED HV SYSTEM
LiFirst 9kWh liquid-cooled high-voltage power system showing the battery module, liquid chiller, coolant piping, high-voltage control box, and PDU output assembly.
PROJECT-SPECIFIC CONFIGURATION Integrated liquid-cooled high-voltage power architecture

Engineering capability example. Final architecture, dimensions, interfaces, and thermal design depend on project requirements.

02 PROJECT-SPECIFIC DEVELOPMENT

LiFirst can develop project-specific liquid-cooling or air-cooling solutions based on cell chemistry, heat generation, continuous and peak power, duty cycle, installation space, ambient conditions, enclosure design, and equipment control requirements.

03 WHY LIQUID COOLING

For many large-format, high-power, or high-duty-cycle battery systems, liquid cooling provides a more controlled method of transferring heat away from the cells and maintaining a more consistent operating temperature across the battery modules.

DESIGN DECISION Cooling method is selected around the battery and equipment operating profile.
SYSTEM INTEGRATION SCOPE

A project-specific liquid-cooled battery system may integrate:

Electrical, thermal, control, mechanical, and auxiliary-power functions are evaluated as one connected system.

01 Battery Thermal Structure

Liquid-cooled battery modules or an enclosure with integrated cooling channels

02 Coolant Circulation

Coolant inlet, outlet, piping, pump, and circulation components

03 Cooling and Heating

Cooling and heating functions for different operating environments

04 Thermal Monitoring

Temperature sensors and BMS thermal monitoring

05 Communication

CAN or RS485 communication with the cooling unit and equipment controller

06 High-Voltage Protection

High-voltage control components, contactors, pre-charge circuits, fuses, and current sensing

07 PDU and Auxiliary Distribution

PDU-based distribution for the cooling unit, pumps, fans, control systems, and auxiliary loads

COMPLETE-SYSTEM EVALUATION Thermal architecture is never assessed in isolation.

The cooling architecture is evaluated together with the battery voltage, capacity, current profile, enclosure, mechanical installation, charging system, communication requirements, and equipment operating cycle.

Discuss Thermal Requirements
HIGH-VOLTAGE PLATFORM ENGINEERING

400V, 800V and Project-Specific High-Voltage Platforms

A high-voltage battery system must be developed as part of the complete equipment architecture—not selected by battery voltage alone.

ANSWER

LiFirst can evaluate common 400V and 800V architectures, as well as non-standard project-specific voltage configurations. The battery voltage must be matched with the motor, controller, charger, insulation system, connectors, high-voltage wiring, protection strategy, installation conditions, and operating requirements.

01 COMMON INDUSTRIAL PLATFORM

400V Battery Systems

400V platforms can be evaluated for lifting equipment, construction equipment, utility vehicles, pump-driven systems, and other industrial mobility applications.

Final configuration depends on power, current, duty cycle, charging architecture, installation space, and control requirements.
02 HIGHER-VOLTAGE ARCHITECTURE

800V Battery Systems

800V platforms can be evaluated for equipment designed around a higher-voltage electrical architecture.

The motor, controller, charger, connectors, insulation, wiring, protection, and other high-voltage components must be compatible with the target voltage.
03 NON-STANDARD CONFIGURATION

Project-Specific Platforms

Non-standard voltage configurations can be evaluated when a common platform does not match the equipment architecture or operating requirements.

Voltage, capacity, current, BMS, communication, enclosure, charging, interfaces, and installation structure are developed together.
400V VS. 800V — ANSWER FIRST

For the same power output, a higher system voltage can reduce current and associated I²R losses. However, the complete electrical system must be designed, rated, and validated for the selected voltage platform.

Motor Controller Charger Insulation Connectors HV Wiring Protection Installation
Submit Voltage Requirements
Close-up CAD rendering of the monitoring and connection interface on a liquid-cooled lifting equipment battery system, including a display, switches, indicators, and external connectors.
CAD rendering of the control and connection panel on a liquid-cooled high-voltage battery system for lifting equipment, showing a display, switches, status indicators, and power connectors.
Detailed CAD rendering of liquid-cooled battery modules, cooling pipework, electrical components, and internal mounting structures in a lifting equipment battery system.

LIQUID-COOLED HIGH-VOLTAGE BATTERY SYSTEM FOR LIFTING EQUIPMENT

A project-specific liquid-cooled battery system developed for lifting and vertical-mobility equipment.

The architecture is engineered around frequent-start loads, peak current demand, duty cycle, installation space, thermal management, service access, external interfaces, and equipment control requirements.

CAD rendering of an integrated liquid-cooled high-voltage battery system for lifting equipment with a modular enclosure, support frame, service doors, lighting, and electrical components.
Open CAD rendering of a liquid-cooled high-voltage battery system showing internal battery modules, cooling lines, control components, and structural integration for lifting equipment.
CAD rendering of a custom forklift battery enclosure with a metal housing, top electrical interfaces, integrated display, lifting brackets, and side handle.

Battery Systems for Lifting Equipment

Lifting equipment can require high peak current, repeated start-stop operation, defined duty cycles, limited installation space, and reliable communication with the equipment controller.
LiFirst can evaluate the battery system around the lifting load, voltage platform, continuous and peak current, expected working time, charging method, mechanical installation, and control requirements.

Open-enclosure CAD rendering of a custom forklift battery system showing internal battery modules, upper electrical components, lifting points, and a metal housing.
APPLICATION ENGINEERING

Custom High-Voltage Battery Systems for Professional Equipment

01

LiFirst develops project-specific high-voltage battery systems for equipment that cannot be reliably powered by a standard battery pack. The battery architecture is evaluated around the actual load profile, installation constraints, charging method, communication requirements, and operating environment.

APPLICATION 01

Battery Systems for Construction Lifts

TYPICAL OPERATING CHALLENGE

Construction lifts and engineering lifting equipment may operate under frequent-start, high-load, and space-limited conditions.

ENGINEERING RESPONSE

The battery system should be matched to the actual working cycle rather than selected by nominal capacity alone.

Duty Cycle Peak Load Installation Space Charging Method
APPLICATION 02

Battery Systems for Refuse Collection Vehicles

TYPICAL OPERATING CHALLENGE

Rear-lift refuse collection vehicles and mobile waste-handling equipment may require dedicated power for moving waste cabinets, lifting mechanisms, and auxiliary vehicle systems.

ENGINEERING RESPONSE

The battery can be evaluated around the lifting mechanism, operating cycle, peak load, installation space, charging method, connector layout, and vehicle environment.

Lifting Mechanism Operating Cycle Connector Layout Vehicle Environment
APPLICATION 03

Battery Systems for Gardening, Spraying and Pump-Driven Vehicles

TYPICAL OPERATING CHALLENGE

Gardening vehicles, municipal spraying vehicles, watering equipment, and mobile high-pressure pump systems require stable power delivery under vehicle-mounted operating conditions.

ENGINEERING RESPONSE

LiFirst can evaluate the battery according to pump voltage, power demand, peak current, runtime, charging method, installation space, and working environment.

Pump Voltage Peak Current Runtime Outdoor Conditions
APPLICATION 04

Custom Batteries for Industrial Mobility and Special-Purpose Equipment

TYPICAL OPERATING CHALLENGE

Industrial mobile platforms, utility vehicles, special-purpose equipment, and non-standard professional systems may require voltage, dimensions, mounting, connectors, communication, or power characteristics that cannot be met by a standard battery pack.

ENGINEERING RESPONSE

LiFirst develops project-specific battery systems around the equipment interface, electrical requirements, installation conditions, and operating profile.

Custom Voltage Mechanical Integration Communication Power Profile
OTHER NON-STANDARD APPLICATIONS Have a different equipment application?

If your equipment requires a non-standard voltage, power profile, enclosure, connector, communication interface, or installation structure, LiFirst can evaluate the project based on your technical requirements.

Submit Your Battery Requirements
Designed Around Protection, Integration and Validation

Safety and reliability in a high-voltage battery project depend on the complete system design — not on a single component or marketing claim. LiFirst evaluates protection logic, BMS monitoring, mechanical integration, and project-specific validation according to the equipment architecture and project requirements.

Protection Design

Project requirements may include overcharge, over-discharge, overcurrent, short-circuit, temperature, insulation, and fault-response protection.

BMS Monitoring

Voltage, current, temperature, cell balancing, fault logic, and communication requirements are evaluated according to the battery and equipment architecture.

Mechanical Integration

Enclosure, connectors, cable routing, mounting, installation space, vibration, and equipment environment are considered during system design.

PROJECT DEVELOPMENT PROCESS

How a Custom Battery Project Moves Forward

Each custom high-voltage battery project begins with a review of the equipment, electrical requirements, installation conditions, charging method, and application environment.

The project can then move through technical evaluation, battery system configuration, sample development, testing, and project-based production according to the confirmed requirements.

01 PROJECT INPUT

Requirement Review

We review the equipment type, application, voltage, capacity, continuous and peak current, expected runtime, charging method, installation space, and operating environment.

02 SYSTEM REVIEW

Technical Evaluation

The electrical, mechanical, BMS, communication, charging, protection, and equipment-integration requirements are evaluated.

03 CONFIGURATION

Battery System Configuration

A project-specific battery configuration is developed based on the confirmed technical requirements.

04 PROTOTYPE

Sample Development

Where required, a sample or prototype can be developed for equipment integration and project evaluation.

05 VALIDATION

Testing and Technical Review

Testing requirements are evaluated according to the battery configuration, equipment interface, operating environment, and project needs.

06 PRODUCTION

Project Production

After the technical requirements and validation needs are confirmed, the project can proceed to small-batch or project-based production.

PROJECT TIMING Timing is defined after the project scope is clear.

Project timing is evaluated after the technical requirements, sample needs, validation scope, quantity, and target delivery requirements are clarified.

Submit Your Project Requirements

Previous Project-Specific Configurations

LiFirst has previously developed project-specific battery configurations including:

The configurations shown are examples of previous engineering capability. They are not fixed retail products or universal solutions for all equipment.

CAD rendering of a custom 244.8V 90Ah high-voltage battery system with a metal enclosure, mounting brackets, and front connectors.
Open-enclosure CAD rendering of a custom 244.8V 90Ah battery system showing internal control boards, electrical components, and connector layout.

Custom 244.8V 90Ah High-Voltage Battery System

A project-specific 244.8V 90Ah battery system developed with a custom metal enclosure, equipment mounting structure, front connector panel, and integrated internal control components.

Engineering Example: Integrated Liquid-Cooled High-Voltage System

A previous project-specific 601.2V / 15Ah battery system was developed as an integrated power assembly incorporating liquid-cooled battery modules, a cooling and heating unit, coolant circulation piping, high-voltage control, and PDU-based power distribution.

The system architecture was developed around the required voltage range, operating power, thermal balance, installation envelope, external interfaces, and equipment integration requirements.

This configuration is presented as an example of engineering capability and is not a fixed retail product.

CAD rendering of a custom 601.2V 15Ah high-voltage battery system with a metal enclosure, lifting points, service panel, ventilation section, and multiple external connectors.
Transparent CAD cutaway of a custom 601.2V 15Ah battery system showing internal electrical components, control hardware, structural supports, service compartments, and external interfaces.
Front-view CAD drawing of the internal electrical component layout in a custom 601.2V 15Ah battery system, including control hardware, protection components, and external connector interfaces.

Custom 601.2V 15Ah High-Voltage Battery System

A previous project-specific 601.2V 15Ah high-voltage battery system developed as an integrated power assembly with liquid-cooled battery modules, high-voltage control, coolant circulation, and PDU-based power distribution.

This configuration is presented as an example of engineering capability and is not a fixed retail product.

192V / 40Ah Project Configuration

Energy:
7.68kWh

Chemistry:
LiFePO4

Architecture:
60S12P

Operating Range:
180–219V

Continuous Current:
50A

Communication:
RS485 / CAN

Structure:
Custom multi-enclosure configuration

Note:
Example of previous engineering capability, not a standard product.

525.6V / 5.2Ah Project Configuration

Chemistry:
NCM

Architecture:
144S1P

Operating Range:
396–604.8V

Continuous Current:
42A

Communication:
RS485

Project Type:
Special-purpose high-voltage equipment

Note:
Example of previous engineering capability, not a standard product.

528V / 166Ah Project Configuration

Chemistry:
NCM

Architecture:
143S1P

Operating Range:
386–600V

Continuous Current:
300A

Communication:
RS485

Structure:
One master enclosure with multiple slave enclosures

Note:
Example of previous engineering capability, not a standard product.

Does LiFirst only sell standard high-voltage battery products?

No. LiFirst’s high-voltage battery business is mainly project-based. Each system is evaluated according to the equipment voltage, capacity, current, duty cycle, charging, BMS, communication, structure, installation, and operating requirements.

Can LiFirst develop both 400V and 800V battery systems?

LiFirst can evaluate 400V, 800V, and other project-specific voltage platforms. The final architecture depends on the complete motor, controller, charger, insulation, connector, wiring, protection, and equipment requirements.

Can you match a battery to an existing motor, pump, or lifting system?

Yes, the project can be evaluated around the equipment voltage, load profile, continuous and peak current, duty cycle, controller, charging method, installation space, and integration requirements.

How is safety evaluated for a custom high-voltage battery system?

Safety requirements are evaluated at the system level, including BMS protection, voltage and temperature monitoring, charging, insulation, connectors, wiring, enclosure, installation, fault logic, and the operating environment.

Can you support sample or prototype development?

Sample or prototype development can be evaluated according to the project stage, technical requirements, integration plan, validation requirements, and expected quantity.

Do you support confidentiality for custom projects?

Confidentiality requirements can be discussed before detailed technical information, drawings, or project-sensitive data are exchanged.

How are certification and compliance requirements handled?

Certification, transportation, and compliance requirements depend on the battery configuration, equipment category, target market, and intended use.

Customers should provide the destination market and required standards during project evaluation. Applicable testing and documentation are reviewed separately for each project.