Custom Battery Packs for Long-Flight Drones: What to Consider

Why Long-Flight Drones Rely on Custom Battery Packs

Long endurance is a core performance factor for industrial drones, especially in tasks such as mapping, power line inspection, and agricultural spraying. Standard batteries often fail to meet the precise requirements of different drone models in terms of size, voltage, capacity, and discharge rate. Custom battery packs offer an effective solution to increase flight time and operational efficiency. With a well-engineered design, custom batteries can also enhance flight safety and system stability.

Cell Selection: The Core of Endurance and Safety

The battery cell serves as the core of a pack, and its performance determines the energy density and lifespan of the entire battery system. Common types include 18650, 21700, and high-power pouch cells. For long-flight drones, it’s essential to use cells with high energy density, stable discharge capabilities, and long cycle life. For example, 21700 cells outperform 18650 in terms of energy density and heat dissipation, making them a preferred choice for high-capacity battery packs.

Balancing Battery Capacity and Voltage Design

Battery capacity directly affects flight time, while voltage impacts motor efficiency and power consumption. A well-balanced configuration—such as 6S or 12S systems—must match the drone’s voltage platform and also take flight duration, current load, and equipment power consumption into account. When designing a custom battery, engineers must balance capacity, voltage, and weight to achieve the best energy-to-weight ratio.

Battery Structure Layout: Adaptability and Heat Dissipation Matter

Long-flight drones often have strict requirements for battery structure. A custom battery must precisely fit the drone battery bay, use lightweight materials to reduce payload, and include effective heat dissipation pathways to prevent overheating during long missions. A smart internal layout of cells and BMS modules improves both structural integrity and maintenance efficiency—especially for heavy-duty drones or prolonged flight scenarios.

Smart Battery Management System (BMS) Ensures Flight Safety

Long endurance requires longer battery operating cycles, making the Battery Management System (BMS) vital. BMS monitors temperature, voltage, and current in real time to prevent overcharging, over-discharging, and short circuits. Advanced BMS systems also support Bluetooth, CAN, or UART communication, enabling real-time data transmission between the battery and flight control system for enhanced operational safety.

Custom Battery Solutions for Long-Endurance Drones

Apsenx specializes in designing and manufacturing lithium battery packs for industrial drones. We offer a wide range of voltage platforms (such as 11.1V, 22.2V, 44.4V) and custom capacity solutions tailored to agricultural, mapping, and inspection applications. By optimizing cell configuration, modular structure, and integrated BMS, our solutions can extend drone flight time by 30% to 50%, while maintaining high safety standards in complex operating environments.

Conclusion

As the demand for extended drone flight time continues to grow, off-the-shelf battery solutions no longer meet the refined needs of diverse applications. Choosing the right battery cell, voltage configuration, structural layout, and BMS system is essential to building a high-performance custom battery pack for long-endurance drones. Apsenx remains committed to delivering professional, efficient, and safe battery customization services—empowering drones to perform at their full potential.

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