Custom PACK process capability
This page focuses on Staricell's custom PACK manufacturing process: cell sorting and matching, structural insulation, controlled soldering, BMS and harness integration, voltage-balance testing, and shipment documentation.
PACK manufacturing process
Instead of repeating product-category content, this section explains how each custom pack is controlled for consistency, structure, heat input, and delivery condition before sampling or production.
Covers incoming inspection, voltage / IR testing, and coded cell matching.
Each cell is screened by voltage and internal resistance to reduce the risk of single-cell overheating, voltage sag, and early degradation under high discharge.
Controls PACK consistency at the source
Covers tab trimming, tape fixing, and barley-paper insulation.
For UAV and industrial-duty vibration, impact, and high-current use, structure fixing and insulation protection improve mechanical stability and electrical safety.
Anti-vibration insulation structure for heavy-duty flight environments
Covers adapter board, tab, power lead, and balance lead soldering.
High-rate pouch cells are sensitive to heat input. A 450-460°C temperature window and < 3s single-point contact control help reduce heat transfer into the cell.
450-460°C control, < 3s per solder point
Covers residue inspection, secondary insulation, voltage-balance testing, and shipment.
Before shipment, each pack is checked for appearance, insulation, protection, and voltage balance against the project's delivery thresholds.
Pack-by-pack voltage-balance and delivery-state check
High-rate and UAV value
Drone battery packs are sensitive to cell consistency, tab soldering, insulation, and voltage balance during climb, payload changes, and high-current output. The goal is not to list parameters, but to reduce the risk of single-cell overheating, voltage sag, weak solder joints, and vibration-related failure.
View UAV battery packsReduces the risk of voltage sag, heat rise, and capacity deviation under high discharge.
Tape fixing, barley paper, and insulation layers help the pack tolerate flight vibration and assembly shock.
Temperature and contact-time control reduce heat transfer into pouch cells.
Customization scope
Pouch, polymer, 18650, 21700, 32700, or project-specified cells.
PACK architecture planned by voltage, capacity, peak current, runtime, and device envelope.
Protection PCB, smart BMS, NTC, SOC, CAN, RS485, or SMBus integration.
XT60, XT90, AS150, balance leads, power harnesses, and custom terminals.
Enclosure, fixing points, tape, barley paper, buffer layers, vibration protection, and service access.
UN38.3, MSDS, shipment labels, model labels, and target-market documentation planning.
Inspection and delivery
RFQ inputs
Global delivery and project documentation
Staricell plans cell supply, pack engineering, BMS integration, test records, and shipment documents around each shipping country, application duty cycle, certification target, and production schedule.
Cell supply, pack engineering, BMS integration, production testing, and export documents are planned around each buyer's shipping country, application, and volume schedule.
Project files can cover UN38.3, MSDS / SDS, shipment labels, test summaries, and documentation paths for CE, IEC, UL, RoHS / REACH, and other requirements.
Operating temperature, continuous / peak current, enclosure protection, connectors, chargers, communication interfaces, and field-service needs are reviewed before mass production.
Cell batch data, matching records, BMS settings, inspection results, and aging summaries can be aligned before sampling or pilot production.
