When a rectangular cell will not fit, our engineering team designs the battery around your enclosure. Round, curved, stepped or notched – we manufacture polymer lithium cells in any non-standard geometry.
Modern devices leave little room for off-the-shelf cells. By co-designing the battery with your mechanical team, we recover 10-30% more volumetric energy density and remove dead space. Acme has shipped over 200 custom geometries for medical, wearable and defence customers.
Same chemistry, same QC. Pick the catalogue when speed matters; pick custom when geometry, capacity or BMS need to be designed around your enclosure.
Discoid Li-Po cells from 8 mm diameter, used in TWS earbuds and smart sensors.
Single or double curvature for wristbands, helmets and curved medical patches.
Multi-thickness footprint to fit around connectors, antennas and PCBs.
Down to 0.4 mm thickness for smart cards, patches and flexible electronics.
Extended ranges available on request — speak to engineering for non-standard targets.
| Parameter | Range | Unit |
|---|---|---|
| Nominal Voltage | 3.7 / 3.8 | V |
| Capacity | 20 – 8,000 | mAh |
| Custom Diameter (round) | 8 – 60 | mm |
| Min. Curvature Radius | R 25 | mm |
| Min. Thickness | 0.4 | mm |
| Max. Discharge Rate | 3C continuous | - |
| Cycle Life | ≥ 500 | cycles |
| Operating Temp | -20 to +60 | °C |
Custom 3D Shape
Round, curved, stepped, notched, asymmetric
Tooling
In-house tooling, 25-35 days for first samples
Capacity Optimization
Energy density tuning per envelope volume
BMS / Connectors
PCM, fuel-gauge IC, custom FPC connectors
NDA & IP
Standard mutual NDA before drawings exchange
Send us a 3D model (STEP/IGES) of the available cavity. Our cell engineers return a feasibility study within 5 working days, including capacity estimate, cycle-life model and BOM cost. After approval we tool prototypes within 4 weeks.
Engineering deep-dives that help your hardware team specify the right cell, the first time.
Why rectangular cells do not fit modern wearable enclosures, and how stepped, L-shaped and U-shaped geometries work — including el
Read more →The mechanical, thermal and EMI trade-offs you encounter when designing a lithium cell below 1 mm thickness for AR glasses.
Read more →How curvature radius, electrode coating and stack geometry affect cycle life in curved Li-Po cells.
Read more →A sober look at AR/VR headset shipment forecasts and what they mean for pouch-cell supply.
Read more →What tooling a custom pouch-cell geometry requires, what each die costs in 2026, and the volume calculation that determines when c
Read more →Why custom battery projects fail when the supplier is engaged too late, and the six-stage workflow that gets a non-standard cell f
Read more →More in this cluster:
Each shipment carries valid UN 38.3 test summary, MSDS and Certificate of Conformity. Additional reports on request.
STEP (.stp) is preferred. We also accept IGES, Parasolid (.x_t) and SolidWorks part files under NDA.
We have shipped 8 mm diameter discoid cells at 25 mAh; 10-15 mm is typical for TWS earbuds at 35-65 mAh.
Yes, after sample qualification we issue a cycle-life specification (commonly 500 cycles at 80% capacity retention) backed by IEC 62133 testing.
Tooling and design-in NRE ranges from USD 1,500-6,000 depending on complexity, and is often waived above committed annual volumes.
Send us your envelope and target spec — engineering will respond within one business day.
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