Military electronic devices operate under the world's most unforgiving combat environments. Reliability, power density, thermal range, and rugged enclosure durability are mandatory requirements. Emerging Power is a trusted USA-based custom battery pack manufacturer delivering high-reliability primary and secondary rechargeable lithium power packs for defense original equipment manufacturers (OEMs).
With over 120 years of collective battery engineering expertise, our U.S. facility designs and builds custom military lithium-ion, lithium-polymer, and LiFePO4 battery assemblies. Every design undergoes complete mechanical, electrical, and environmental testing to guarantee uninterrupted mission-critical operation on land, in the air, and at sea.
Our defense power solutions are engineered to meet strict military specifications (MIL-STD-810, MIL-PRF-32052) to resist shock, vibration, humidity, and extreme thermal fluctuations.
Emerging Power designs custom lithium-ion and lithium primary battery packs optimized for lightweight ergonomics, long operational runtime, and bulletproof reliability in tactical combat zones.
Ultra-high energy density Li-Po and custom 21700/18650 packs optimized for long endurance flight times, high discharge rates, and weight-sensitive reconnaissance platforms.
Rugged rechargeable power packs for encrypted software-defined radios (SDR), handheld transceivers, and soldier wearable tactical communication networks.
High-capacity internal and hot-swappable battery packs designed for battlefield field terminals, head-mounted displays (HMD), and command-and-control rugged tablets.
Ultra-reliable lithium primary and secondary battery packs supplying stable voltage to night vision goggles (NVG), thermal weapon scopes, and infrared target designators.
Scalable LiFePO4 battery storage systems providing zero-interruption backup power for tactical command centers, radar units, and mobile communications trailers.
Durable battery packs engineered to withstand continuous impact, vibration, and rapid discharge requirements in live-fire simulation and automatic fire suppression systems.
Modern tactical gear demands continuous operational capability without adding excessive weight to a soldier's equipment load. Emerging Power addresses these challenges through advanced cell chemistry selection and custom smart BMS integration.
We collaborate with premium cell suppliers (including Tier-1 lithium-ion, silicon-anode NanoGraf 18650-M38, and Amprius ultra-high energy cells) to deliver maximum power-to-weight ratios for defense OEMs.
Custom Battery Management Systems monitor cell balance, state of charge (SoC), state of health (SoH), over-voltage, short-circuit, and thermal safeguards. Data protocols (SMBus, HDQ, CANBus) interface seamlessly with host equipment.
Using 3D rapid prototyping, ultrasonic plastic welding, and CNC machined aluminium or ruggedized polymers, we fabricate housings that resist IP67/IP68 water submersion, salt spray, and ballistics shock.
For non-rechargeable applications requiring 10+ year shelf life in un-powered storage, we engineer customized Lithium Thionyl Chloride (Li-SOCl2) and Lithium Manganese Dioxide (Li-MnO2) battery packs.
To ensure guaranteed field performance, Emerging Power subjects every military battery design to stringent electrical, environmental, and mechanical validation testing prior to deployment.
100% cell testing for internal resistance, capacity, voltage consistency, and visual integrity prior to pack assembly.
Automated weld verification, insulation resistance checking, and programmed BMS calibration at key assembly stages.
Full operational cycle testing, thermal chamber aging, and UN 38.3 transport safety certification compliance.
Whether you require a custom ITAR-compliant battery pack for a new defense project or need high-volume assembly for military equipment, our engineering team in Hackensack, NJ is ready to discuss your design requirements.
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