There are billions of electronic devices globally, with just the U.S. consumer electronics market generating $200 billion in 2024. Many electronic goods require batteries to function, from mobile devices and smart thermostats to hearing aids and health monitors. Mastering the art of battery packaging is essential for manufacturers of consumer goods, medical devices, laboratory equipment, military technology, and countless other electronic products.
Battery packaging design has two main goals: to protect batteries from damage during transport and to prevent hazards caused by the batteries themselves, such as leakage or fires. Several factors determine the right type of packaging for batteries and the necessary specifications to achieve your objectives.
Shipping and logistics require careful planning to minimize risks and maximize efficiency. Damage to components should be a key factor you consider in risk assessments. Certain products are especially sensitive to specific types of damage, such as:
This guide focuses on dry and rechargeable batteries commonly used in electronics manufacturing, such as lithium-ion, NiMH, and silver-oxide.
Logistics concerns for battery packaging design depend on whether your company ships the batteries as self-contained units or alongside electronic devices. Combination packaging is possible thanks to customized thermoplastic trays or specialized paperboard inserts.
When shipping batteries and electronics goods together, the design of primary packaging, secondary packaging, and/or insulating layers must prevent accidental activation during transport. Even battery-only packaging must keep the products safe from discharges and short-circuiting.
Certain types of batteries (especially lithium-ion variations) have special considerations for transport and storage. Packaging must provide adequate impact resistance, prevent friction or vibration, and safeguard against temperature extremes. There are also pressure factors for air transportation.
Manufacturers must adhere to regulations when packaging and transporting batteries, especially lithium-ion batteries:
The IATA and ICAO consider all lithium-ion and lithium-metal batteries to be hazardous materials, which means battery packaging design must meet Dangerous Goods Regulations, and manufacturers must also follow special labeling and MSDS requirements.
Knowing how to ship electronics is only part of the challenge when dealing with lithium-ion batteries. The process of designing battery packaging is also complex because of the wide range of materials, thicknesses, and configurations available.
One of the greatest advantages of lithium-ion batteries is their high energy density. This makes them ideal for powering everything from smartwatches and mobile devices to cordless drills and precision equipment. But this high energy storage capacity and rechargeability also mean significant risks during transportation:
Effective packaging can mitigate these dangers, but it takes careful engineering to determine the correct specifications for different battery types, sizes, and capacities.
It’s not enough to choose a package that is a good fit physically for the battery’s shape. As hazardous materials, the majority of lithium-ion and lithium-metal batteries must meet robust packaging standards. Packaging for dangerous goods transportation must undergo several tests:
One thing that makes these regulations challenging for organizations to implement is that the specific testing requirements depend on the charge capacity of the battery. Whether you ship by rail, roadway, sea, or air matters, too.
Lithium-ion batteries under 100 Watt-hours (or cells under 20 Wh) have certain exemptions. For lithium-metal cells, exemptions apply to cells under 1 gram or batteries below 2g.
Batteries must have both primary and secondary packaging, exclusive of any dividers used to separate the batteries from other devices. Primary battery packaging comes into direct contact with the battery or cell. Examples include:
Keep in mind that batteries can’t be transported in any packaging with an inner metal layer. If your electronic product requires EM protection, you must package it separately from the batteries.
Secondary packaging is the outer box for the product, generally made of fiberboard or cardboard. It’s also common to use fill to further cushion packages, like ESD-resistant foam.
Medical device manufacturers often use sealed thermoplastic trays to hold individual cells, and the trays are stackable for enhanced stability. These trays are then placed in precise-fitting secondary packaging, such as durable cardboard boxes or wood containers, to better resist impacts and vibrations.
Batteries for precision medical devices, optical components, and scientific equipment can have a high cost. Investing in exceptional protection makes sense. At Ready-Made Plastic Trays, we have decades of expertise in designing high-performance packaging solutions. Request a free sample to see the quality of our custom plastic trays for electronics for your products.