Custom Lithium Battery Trends in Brazil: Insights from EXPOSEC 2026 for Security & IoT OEMs

VTCBATT just returned from EXPOSEC 2026 in São Paulo, Latin America’s premier security and IoT trade fair.

From 1st June to 3rd June 2026, we met with many Brazilian OEM manufacturers in the fields of security, IoT, and solar, who were seeking reliable custom lithium battery solutions. Brazil’s demand for customized lithium battery packs is growing quickly, especially in security systems, IoT gateways, tracking devices, solar-powered equipment, and backup power applications.

In this article, we share the key battery trends, technical requirements, and market insights we observed from the exhibition floor.

Custom Battery Demands in Brazil’s Security and IoT Sectors

Brazil has become one of the fastest-growing IoT markets in Latin America. Brazilian digital transformation spans many industries, including industrial automation, smart utilities, logistics, agriculture, security, and smart cities. Many Brazilian IoT solution providers develop both their own hardware and cloud-based management platforms. 

Many Brazilian IoT manufacturers and industrial electronics companies visited our booth during Exposec 2026. They want tailor-made lithium battery packs designed for compact enclosures, higher energy density, extended runtime, and wide operating temperatures. Furthermore, our on-site engineers provided them with various technical proposals tailored to their concerns. Based on their power consumption and designed service life, we provided them with a detailed, wide-temperature battery proposal for a rechargeable Li-ion battery and a non-rechargeable Li-SOCl2  battery. Based on their compact enclosure shape, we recommended a 3.7V lithium polymer battery or a 3.0V LiMnO2 battery in any custom size they design.

Our Brazilian local, Portuguese-speaking team was a big advantage at the fair. Eliminating language barriers allowed us to discuss complex technical details easily—such as battery cell dimensions, custom wiring, and charging parameters. Then we can quickly finalize the exact project requirements during the fair.

Although some Brazilian IoT devices have similar functions, their hardware designs differ significantly in battery size and capacity requirements; several major market shifts recur. These key takeaways show exactly where Brazil’s industrial electronics and power backup sectors are heading.

Trend 1: Why Brazilian Security & IoT OEMs Are Choosing Custom Lithium Battery Packs

During technical discussions at EXPOSEC 2026, many Brazilian OEM electronic manufacturers initially developed their products using standard off-the-shelf lithium batteries. As their products matured, however, they encountered limitations in runtime, installation space, operating temperature, charging performance, and long-term reliability. 

Very few clients now ask for standard batteries in stock in Brazil. Instead, they asked, “Can you engineer a battery pack around our housing?” To meet these demands, VTCBATT provided custom engineering during the show across several critical specs:

• Mechanical & Housing: Custom sizes, custom connector models, cable-length assemblies, and waterproof packaging enclosures.
• Electrical & Smart Control: Stable operating voltages, higher-capacity optimization, and intelligent BMS integration via CAN Bus or SMBus communication.
• Environmental Endurance: Wide-temperature operation for outdoor equipment. 3% ultra-low self-discharge designs for long standby operation of up to 10 years.

The conversations at EXPOSEC 2026 confirmed a clear market shift: Brazilian OEM manufacturers are no longer looking for battery suppliers—they are looking for engineering partners capable of designing complete custom power solutions for their products. 

Trend 2: Why Brazil’s Security Industry Is Switching from SLA to LiFePO₄ Batteries. 

One topic came up repeatedly during our conversations at EXPOSEC 2026.

Many Brazilian manufacturers of alarm systems, CCTV equipment, access control devices, and backup power products were no longer asking whether they should use lithium batteries. Instead, they wanted to know how quickly they could replace traditional sealed lead-acid (SLA) batteries in their next product generation.

Although LiFePO₄ batteries have a higher initial purchase cost, most customers understand that they can get a much lower price per cycle life and reduce much maintenance costs.

Their priority is reducing maintenance, extending service life, and designing smaller, more reliable products that remain competitive over the next five to ten years.

Three technical requirements appeared consistently across different projects.

-3XLonger Service Life

Standard backup batteries use lead-acid batteries. A lead-acid battery requires frequent maintenance and replacement. Eventually, the total cost of installing equipment in schools, office buildings, factories, and remote monitoring sites is both expensive and time-consuming. Security manufacturers are very interested in the LiFePO4 batteries with 6000 cycle times and a 10-year service life. 

-⅓ Smaller and Lighter Battery Packs

Security products continue to become thinner and more compact. Several manufacturers told us that the available battery compartment had become one of the biggest design constraints. Higher-energy-density LiFePO₄ and lithium-ion battery packs provide greater flexibility when designing modern alarm panels, access control systems, and surveillance equipment.

-2XFaster Charging and Higher Backup Availability

For security devices, restoring backup power quickly after a power outage is increasingly important. Compared with conventional SLA batteries, LiFePO₄ battery packs can generally accept higher charging currents and return to full capacity much faster, helping critical systems recover sooner.

These changing requirements were reflected across several product categories discussed during the exhibition:

• Alarm Control Panels — replacing conventional 12V 7Ah SLA batteries with drop-in 12V 7Ah LiFePO₄ battery packs.
• CCTV and Video Surveillance Systems — compact backup batteries designed to keep recording during utility power interruptions.
• Access Control and Smart IoT Devices — custom lithium polymer batteries for wireless detectors, smart locks, access terminals, and connected security equipment.

The conversations at EXPOSEC 2026 revealed a broader market transition. Brazilian security manufacturers are no longer evaluating batteries as standard replacement parts. Instead, they are treating battery technology as an integral part of product design, reliability, and long-term operating cost. For custom battery manufacturers, this means success depends not only on supplying cells, but also on providing engineering support throughout the product development process.

Trend 3: IoT Products Continue to Demand Smaller and Smarter Battery Designs

Many industrial IoT manufacturers in Brazil, such as BWS IoT and X3 Tech, have very strong hardware development capabilities. They no longer just purchase standard batteries; they want to design their product with custom batteries featuring ultra-thin thickness, ultra-low self-discharge, wide temperature operation, and dedicated smart BMS configurations.

IoT Asset Trackers Are Becoming a Fast-Growing Battery Application in Brazil 

One application attracted our attention throughout EXPOSEC 2026: IoT asset tracking devices.

Several visitors brought their asset tracker prototypes or existing products to our booth. We discussed battery upgrade options with our engineering team. In most cases, ultra-thin lithium batteries can fit in compact enclosures while providing long standby time, stable wireless communication, and reliable operation in demanding field environments.

Many of these trackers are designed for banking, cash logistics, high-value asset protection, fleet management, and other security-sensitive applications, where battery reliability directly affects device performance and maintenance intervals. This banking-level integration dictates a steep vector in future volume demand. To seamlessly slide into credit-card-sized enclosures or wallet-thin form factors, these industrial asset tags rely heavily on ultra-thin IOT batteries—typically engineered to a strict 1.0 mm footprint.

At VTCBATT, we eliminate standard off-the-shelf sizing limitations. We offer 100% custom-dimension flexible lithium polymer cells, allowing engineers to optimize capacity and active BMS protection inside rigid micro-spaces.

Battery design is becoming an important part of product engineering instead of a simple purchasing decision.

Trend 4: Solar-Powered Applications Continue to Expand Across Brazil

Solar-powered electronic equipment attracted considerable attention throughout EXPOSEC.

Customers introduced projects involving:

• Solar security cameras
• Solar street lights
• Remote monitoring stations
• Smart agriculture
• Environmental monitoring
• Off-grid communication equipment

Outdoor products have more rigorous requirements on battery performance. The battery needs an ultra-low self-discharge rate to support a 10-year service life.

Cycle life, charging efficiency, operating temperature, enclosure protection, and long-term reliability become much more important than battery price alone.

Trend 5: Engineering Support Has Become More Important Than Price

Perhaps the most interesting observation during EXPOSEC 2026 was that many discussions focused on engineering rather than pricing.

Customers frequently asked questions such as:

• Which battery chemistry is most suitable?
• Can the battery fit inside our enclosure?
• Can the runtime be extended?
• Can BMS communication be added?
• How should charging parameters be optimized?
• Which certifications are required?
• Can samples be produced quickly?

These conversations demonstrate that many OEM manufacturers are seeking technical collaboration rather than simply purchasing batteries.

The Most Common Battery Applications Discussed at EXPOSEC 2026

Project Snapshots from EXPOSEC 2026: Three Battery Design Projects with Brazilian OEM Manufacturer

One of the most valuable aspects of EXPOSEC 2026 was the opportunity to discuss real product development challenges with Brazilian OEM manufacturers. Although every customer was developing different products, many of the engineers shared a common theme: the battery must be designed around the product—not the other way around.

Below are three representative application scenarios discussed during the exhibition.

GPS Tracker: Balancing Compact Size with Long Standby Time

For a Brazilian client developing ultra-thin asset trackers, the primary bottleneck was a strict 1.0 mm thickness limit inside the housing. Standard 3.7V LiPo cells simply couldn’t deliver the required runtime. Our lead engineer, Sunny, bypassed this constraint by customizing a 4.2V High-Voltage (HV) LiPo battery, successfully boosting energy density by 15% within the exact same footprint. This tailor-made solution not only extended the tracker’s standby cycles but also ensured stable discharge performance under extreme outdoor temperatures of up to 80°C. 

 The battery not only fits within a very limited enclosure but also provides long standby time and stable performance under outdoor operating conditions.

Rather than simply increasing battery capacity, the discussion focused on optimizing the lithium polymer cell dimensions, reducing standby power consumption, selecting an appropriate protection circuit, and customizing the connector to match the existing PCB layout. For products such as GPS trackers, every millimeter inside the enclosure is valuable, making battery size optimization just as important as energy capacity.

This conversation highlighted why custom lithium polymer batteries remain a preferred solution for GPS tracking applications, where flexible dimensions and high energy density are essential.

Industrial IoT Gateway: Integrating Battery Performance with Intelligent Power Management

Another interesting discussion came from an industrial IoT gateway manufacturer developing equipment for remote monitoring and data collection.

Unlike compact sensors, IoT gateways typically integrate communication technologies such as 4G/LTE, Wi-Fi, LoRa, Ethernet, or RS485. These functions create higher peak current demands and require more sophisticated power management than many standard battery-powered devices.

Instead of focusing solely on battery capacity, the engineering discussion covered peak discharge capability, operating temperature, charging strategy, installation space, and long-term reliability. We also discussed the possibility of integrating a smart Battery Management System (BMS) with communication interfaces such as SMBus, CAN Bus, or RS485, enabling the host system to monitor battery status when required.

As industrial IoT devices continue to become smarter and more connected, battery systems are evolving beyond simple power sources. They are becoming an integral part of the overall energy management architecture, supporting communication, diagnostics, and long-term operational reliability.

Solar Surveillance System: Designing for Outdoor Reliability

Solar-powered surveillance systems were another frequently discussed application throughout the exhibition.

One customer introduced a remote monitoring project that relied entirely on solar power in locations without access to the electrical grid. Unlike indoor backup systems, this application required the battery to withstand high ambient temperatures while delivering reliable performance through continuous daily charge and discharge cycles.

Rather than simply selecting a larger battery, the engineering discussion focused on choosing the appropriate battery chemistry, optimizing cycle life, improving charging efficiency, and designing a battery pack capable of stable long-term outdoor operation.

For projects like this, LiFePO4 batteries are often chosen for their long cycle life, excellent thermal stability, and high operational safety. However, the final battery configuration always depends on factors such as solar panel output, charge controller settings, load power consumption, available installation space, and the required backup time.

This discussion reflected another important trend observed during EXPOSEC 2026: as solar-powered security and remote monitoring systems continue to expand across Brazil, battery customization is becoming a critical part of overall system design rather than simply a component selection process.

A Common Theme Across Different Industries

Although these projects served different markets—including GPS tracking, industrial IoT, and solar-powered surveillance—they all shared one common requirement: there is no one-size-fits-all battery solution.

Modern OEM products increasingly require batteries that are tailored to the application’s mechanical structure, electrical characteristics, operating environment, safety requirements, and expected service life. As a result, battery manufacturers are expected to provide not only production capacity but also engineering expertise throughout the product development process.

At EXPOSEC 2026, many of the most meaningful conversations were not about standard battery models or pricing. Instead, they focused on designing safer, more reliable, and better-integrated battery solutions for the next generation of security, IoT, and renewable energy products.

Frequently Asked Questions from EXPOSEC 2026 Visitors

Can lithium batteries replace traditional SLA batteries?

In many backup power applications, yes. LiFePO4 batteries typically offer longer cycle life, lighter weight, faster charging, and lower maintenance than sealed lead-acid batteries. However, compatibility should be evaluated according to charging voltage, discharge characteristics, and system requirements.

Which battery chemistry is best for GPS tracking devices?

There is no universal answer. Small GPS trackers often use lithium polymer batteries because they provide flexible dimensions and high energy density. Long-life outdoor tracking devices may use primary lithium batteries for extended standby operation.

How long does custom battery development usually take?

Prototype development generally begins after confirming the product’s electrical specifications, mechanical dimensions, operating environment, connector type, and certification requirements. Development time depends on project complexity and component availability.

Can battery dimensions be customized?

Yes. Custom battery packs can be designed according to available installation space, including cell arrangement, cable routing, connector selection, enclosure limitations, and required capacity.

Do security and IoT batteries require a Battery Management System?

Small single-cell batteries may only require basic protection circuitry, while multi-cell lithium battery packs typically require a BMS to manage charging, discharging, balancing, and protection functions.

What information is needed before designing a custom battery?

The most helpful information includes:

• Product dimensions
• Required operating voltage
• Capacity target
• Maximum discharge current
• Charging method
• Operating temperature
• Connector specification
• Available installation space
• Communication requirements
• Safety certification requirements

Providing these details early helps reduce development time and improves design accuracy.

Why More Brazilian OEM Manufacturers Are Choosing Custom Battery Solutions

Industrial products continue to become smaller, smarter, and more specialized.

As a result, battery packs are no longer generic components.

A custom-designed battery can improve:

• Product reliability
• Available installation space
• Backup operating time
• Safety performance
• Production efficiency
• Long-term maintenance cost

For many OEM manufacturers, battery design has become an important part of overall product development.

How VTCBATT helps Brazilian OEMs navigate ANATEL battery certifications？

Compliance-Ready Designs: We engineer custom battery packs that meet IEC 62133 and IEC 61960-3 standards, as required by ANATEL for approval.

• Exact Testing Samples: We provide the precise number of certified prototypes and raw cells (typically 34 packs + 10 cells) required by Brazilian labs for destructive testing.
• Full Documentation: We supply all necessary technical data, including ISO 9001 certificates, battery datasheets, and UN38.3 reports, to streamline filings with the OCD (Designated Certification Body).
• Smart BMS Integration: Our built-in Battery Management Systems feature advanced thermal and overcharge protection, ensuring packs easily pass Brazil’s strict high-temperature safety tests.
• Factory Audit: VTCBATT is an ITS- and SGS-audited factory. Our modern facilities can pass the ANATEL factory audit.

We have the ability to handle the manufacturing-side compliance. Our Brazilian partners can shorten the standard 3- to 4-month ANATEL approval timeline and launch products faster.

About VTC POWER

VTC POWER specializes in custom lithium battery solutions for OEM and industrial applications.

Our engineering team supports customers throughout the complete battery development process, including lithium polymer cell selection, lithium-ion battery pack design, LiFePO4 battery customization, BMS integration, connector assembly, sample development, testing, and mass production.

Our battery solutions are widely used in security systems, GPS trackers, IoT devices, medical equipment, industrial electronics, UPS backup systems, robotics, and renewable energy applications.

Looking Beyond EXPOSEC 2026

EXPOSEC 2026 confirmed that Brazil remains one of the most dynamic markets for security technology, IoT innovation, and solar-powered equipment in Latin America.

More importantly, the exhibition reinforced a broader industry trend: OEM manufacturers are increasingly seeking battery partners who can contribute engineering expertise, customization capability, and long-term technical support—not simply supply standard battery products.

The conversations we had throughout the exhibition will continue well beyond the event itself, shaping future collaborations and helping develop battery solutions that better meet the evolving needs of Brazil’s security, IoT, and renewable energy industries.

Watch our EXPOSEC 2026 highlights video below to see our on-site battery demonstrations and engineering discussions with Brazilian OEMs 

Dr. David Chen

Senior Technician (CTO)

Dr. David Chen is a senior engineer with 20 years of experience in lithium battery R&D and 10 years in power system development. He is proficient in the complete technical process of lithium battery manufacturing to commercial lithium battery system deployment.