This study investigates the efficacy of variable pulse charging (VPC) on charging 18,650 secondary battery packs (12 V, 20 Ah) with NMC chemistry. VPC, a modern technique applied to secondary battery charging, aims to mitigate effects like a thermal runaway and thermal propagation caused by increased charging temperature. VPC involves varied duty factors (10 % to 90 %), charging rates (0.5C, 1C, 1.5C), and an optimal switching frequency determined through frequency response analysis. Its digital model is based on in situ electrochemical impedance spectroscopy measurements and MATLAB/Simulink simulations. At charging rates of 0.5C (10 A), 1C (20 A), and 1.5C (30 A), the temperature of the battery pack reaches 42.46 °C, 57.87 °C, and 70.37 °C, respectively. However, implementing VPC at a 50 % duty factor yields temperature reductions of 3.66 °C, 5.06 °C, and 5.42 °C, respectively. Similarly, employing VPC at a 10 % duty cycle results in temperature reductions of 11.2 °C, 17.7 °C, and 19.1 °C, respectively. The results indicate a significant reduction in charging temperature compared to constant current charging. Furthermore, the 1C condition is validated using a custom-made dual active bridge DC-DC variable pulse charger. In conclusion, applying optimal frequency-based VPC with specific duty factors demonstrates the potential to reduce temperature elevation during battery pack charging significantly.