A basic 10,000-mAh power bank can cost $6–$12 to build, while PD fast-charge versions run $10–$20 before certifications.
Building a portable charger looks simple from the outside—a shell, a battery, and a couple of ports. The real spend sits in the cells, power electronics, protections, and the quiet line items like testing, packaging, and freight. Below is a clear, parts-down view of what makers pay to produce a mainstream 10,000–20,000-mAh unit, plus what pushes costs up or down.
Bill Of Materials: What Drives The Per-Unit Cost
The lithium-ion cells dominate the bill. After that come the USB-C or Micro-USB interface chips, the battery protection board (BMS), the PCB, connectors, casing, LEDs, and small passives. Labor and yield add a layer on top. The table below maps realistic factory-side ranges for a 10,000-mAh “value” build and a 20-watt USB-C PD build.
| Component | 10,000-mAh Value Build (USD) | 10,000-mAh PD ~20W (USD) |
|---|---|---|
| Lithium-Ion Cells (≈37 Wh total) | $3.50–$5.00 | $4.00–$6.00 |
| BMS / Protection Board | $0.30–$0.80 | $0.60–$1.20 |
| USB Power ICs (Micro-USB or basic USB-A) | $0.20–$0.60 | — |
| USB-C PD Controller + Power Path | — | $1.70–$3.50 |
| PCB, Passives, LEDs | $0.35–$0.70 | $0.50–$0.90 |
| USB-C / USB-A Connectors & Cable Pigtail (if included) | $0.20–$0.50 | $0.35–$0.80 |
| Enclosure (ABS/PC), Buttons, Label | $0.50–$1.20 | $0.70–$1.50 |
| Assembly Labor (line + QA) | $0.40–$0.90 | $0.50–$1.10 |
| Factory Overhead & Yield (scrap allowance) | $0.25–$0.60 | $0.30–$0.70 |
| Parts Subtotal (ex-works) | $5.70–$9.30 | $9.00–$15.70 |
Those spreads reflect cell pricing swings, choice of ICs, and volume. A boutique run of 1,000 units lands at the upper end; a 50,000-unit order trims dollars off the silicon and plastics lines.
Why The Battery Line Matters Most
Cells set the floor. Industry surveys put average pack pricing near the low hundreds per kilowatt-hour. A 10,000-mAh bank stores about 37 watt-hours, so even small shifts in the global $/kWh number ripple into a few dollars per unit. Pair that with supply dynamics and you get the wide ranges buyers see across seasons.
Translating kWh To A Power-Bank Pack
Here’s the rough math many buyers use on quotes: take the current $/kWh benchmark and multiply by 0.037 kWh for a 10,000-mAh pack. If market pack pricing sits near $115/kWh, the cells alone land a bit above $4 for that capacity tier, before assembly and protection hardware.
Cell Choices: Pouch Vs. 18650
Manufacturers often choose a flat pouch cell for thin cases, or 18650 pairs for easy sourcing. Flat packs simplify wiring and packaging. Dual 18650s can be cheaper in periods when cylindrical supply gluts. Either way, quality bins and built-in protection affect scrap rates and warranty returns, which feeds back into cost.
Electronics: Where Fast Charging Adds Dollars
A low-cost bank with USB-A output runs on a charge controller and a modest boost converter. A USB-C PD design needs a standards-compliant controller, power path management, and tighter thermals. That’s why PD 20W jumps a couple of dollars on the BOM. Go above 30W and the silicon, inductors, and thermal design scale up again, nudging both parts and enclosure costs.
Protection And Compliance Basics
The BMS monitors cell voltage, current, and temperature. It is a small board, yet it carries the safety margin for over-charge, over-discharge, and short-circuit events. Skimping here saves cents and risks dollars. Reputable packs pair that BMS with a casing that resists heat and drops, plus fuses or PTCs on the high-current path.
Ports, Cables, And Mechanicals
Connectors look trivial on a spreadsheet, but high-cycle USB-C receptacles, tight tolerances on cutouts, and a secure strain relief on any included cable keep returns low. Plastics range from matte ABS to PC blends with flame retardants. Thicker walls and internal ribs protect the pack during a bag drop, which cuts warranty costs down the line.
Hidden Costs Beyond The BOM
Two buckets shape the “real” cost per unit: regulatory testing and logistics. Lithium packs ship under dangerous goods rules. That brings testing and paperwork. Then come packaging, labeling, and freight premiums, especially for air cargo.
Testing And Certifications: What Makers Budget
Most brands budget for transport testing and at least one safety standard. UN 38.3 covers transport safety and is a must for air freight. Many retailers ask for a safety mark such as UL 2056 or IEC 62133-2. These programs take time, samples, and lab fees. The second table summarizes common ranges and how the spend spreads across a run.
| Program | Typical Lab Fee (USD) | Amortization / 10,000 Units |
|---|---|---|
| UN 38.3 Transport Testing | $800–$2,000 | $0.08–$0.20 per unit |
| UL 2056 Safety (Power Banks) | $10,000–$20,000+ | $1.00–$2.00 per unit |
| IEC 62133-2 / CE Route | $6,000–$10,000 | $0.60–$1.00 per unit |
| Packaging, Labels, Manuals | $0.25–$0.60 per unit | $0.25–$0.60 per unit |
| Dangerous Goods Freight Surcharge | $0.20–$1.00 per unit | $0.20–$1.00 per unit |
Spread these fees across multiple SKUs and the per-unit load improves. Short runs pay a steep premium. Many brands align releases so a single test report covers several cosmetic variants that share the same cell, board, and casing materials.
Worked Examples: What A Maker Pays
10,000-mAh Budget Model (USB-A + Micro-USB)
- Parts subtotal: around $6–$8 at mid volumes
- Packaging and inserts: $0.30–$0.50
- Factory QA and yield: $0.30–$0.50
- Cert amortization (UN 38.3 only): $0.10–$0.20
- Ex-works total: roughly $6.70–$9.20
Add freight, duty, and a modest brand margin, and a $14.99 retail tag comes into view for value channels.
10,000-mAh USB-C PD 20W Model
- Parts subtotal: roughly $10–$14
- Packaging and inserts: $0.30–$0.60
- Factory QA and yield: $0.40–$0.70
- Cert amortization (UN 38.3 + UL 2056): $1.30–$2.20
- Ex-works total: about $12.00–$17.50
Retail often lands near $24.99–$34.99 depending on brand pull, ports, cable-in-box, and warranty.
Capacity Steps And How Cost Scales
Doubling capacity from 10,000 to 20,000 mAh adds another ~37 Wh of cells and a case with more volume. The PD electronics stay similar unless output power rises. So the jump is mostly in cells and casing, with a smaller lift in freight due to weight.
What About 30W, 45W, Or 65W Output?
Raising output means bigger inductors, stronger FETs, and tighter thermal design. Expect another $1–$4 on the BOM as you step from 20W to 45W, then a further $2–$5 for 65W, plus thicker plastics or metal frames to handle heat and drop tests.
How Standards And Shipping Rules Shape Design
Two references guide both hardware picks and labeling. The IATA lithium battery guidance outlines packing instructions and labels for air transport. On the hardware side, the USB specs define how ports negotiate charge rates and safe draw. When a bank claims 1.5 A on legacy ports or advertises USB-C output, the controller and test plan must match the spec language.
Cell pricing trends also move the needle. The BNEF battery price survey tracks pack costs across the industry, and makers often shadow that index when quoting new seasons. A cheaper $/kWh readout gives negotiators room to push the cell line down.
Ways To Trim Cost Without Hurting Safety
Pick Realistic Power Targets
If your audience charges phones and earbuds, 20W hits the sweet spot. Pushing to 30W only helps a subset of devices and adds BOM dollars that many shoppers won’t use.
Anchor On A Common Cell Size
Choose a high-volume cell model from a mainstream vendor. That supports multi-sourcing and better lead times. It also reduces the risk of last-minute substitutions that might force a retest.
Reuse A Qualified Platform
Once a board and cell combo passes UN 38.3 and a safety standard, keep the internals the same while varying color, finish, and packaging. You get a family of SKUs while amortizing the lab spend.
Design For Assembly
Snap-fits, fewer fasteners, and clear cable routing shave seconds per unit. Small tweaks add up across a long run and help line yield.
Common Cost Pitfalls
- Thin plastics that crack on a corner drop. Saves cents, risks returns.
- No room for thermal pads near the inductor. Leads to hot spots and throttling.
- Over-ambitious spec sheet. Claiming 65W on a small pack forces pricier silicon and thicker walls.
- Skipping sample aging. A short burn-in can catch early cell drift that would become field failures.
Quick Reference: Cost Ranges By Feature Set
10,000-mAh, 1× USB-A Output
Factory cost lands near $6.50–$9.50 across typical runs. Great for promos and value retail.
10,000-mAh, USB-C PD 20W + USB-A
Expect $12–$17.50 ex-works. Branded retail often adds a better cable and a longer warranty to justify price bands above $25.
20,000-mAh, USB-C PD 30–45W
Plan for $18–$28 ex-works with a solid cell pack and a thicker case. Freight moves up with weight, so ship by sea when timelines allow.
Bottom Line For Planners
A no-frills 10,000-mAh bank sits in the high single digits to produce. A polished USB-C PD model with clean thermals, good plastics, and current safety paperwork sits in the low to mid teens. Add lab amortization and logistics, and the full landed cost still leaves room for a fair retail tag.
Method Snapshot
Ranges above blend current $/kWh references with live distributor pricing for PD controllers and data from battery test labs on program scope and timelines. Figures reflect mainstream supply chains and exclude sales tax, retailer fees, and brand marketing.