Rapid, first-article lithium systems for teams on real timelines. Configurable modules and packs for aerospace, defense, robotics, and labs, designed, built, and documented without 18-month lead times.
EVolve Battery Systems is a U.S.-based battery engineering company headquartered in Boulder, Colorado. The company specializes in custom lithium-ion battery systems for aerospace, defense, industrial, and research applications. EVolve designs and manufactures two primary product lines: MonoLith, a turnkey aluminum-enclosed battery pack system, and Lithium Block, a wire-bonded modular battery platform. Customers configure systems through the PackForge platform and submit requests for quote directly from the site.
Modular platforms that accelerate integration and reduce risk for critical applications.
Configurable air cooled 18650 modules (energy/power variants)
21700 liquid cooled, IP67 platform (custom S/P, HVIL, Pre-charge, Configurable BMS)
Pouch-based, liquid-cooled, IP67 pack platform for higher energy densities
Datasheets + manuals + UN38.3 summary + handling guide
We excel where speed, flexibility, and direct engineering access matter most.
When standard solutions don't fit your unique requirements
We specialize in OEM and fleet programs where you're building a repeatable product or vehicle platform. That may start with a handful of prototypes and pilot units, but there's a clear path to multiple builds, not one-off personal projects.
Built into our process from day one, not afterthoughts
No layers of sales or project management. Talk directly to builders.
Real durations, not marketing timelines. From concept to shipping hardware.
1–3 days
Requirements review and feasibility
3–7 days
CAD, specs, and build plan locked
6–10 weeks
Assembly and integration
-1-2 days
Validation and documentation
IATA/DOT compliant
Proper hazmat documentation
Real projects, real timelines, real results. Anonymized for confidentiality.
Envelope-constrained design, FR-4 creepage per IEC, shipped with UN38.3 handling docs.
CAD→bench power-up: 5 weeks
Copper busbar + thermal spreader update; peak current ↑ 32% with same footprint.
Passed functional test first try
100 V segment architecture, fuse placement, Universal BMS compatibility.
Cleared tech inspection
Transparent about what's certified now and what's program-specific.
Lithium Block™ 5P/6P/10P (UN38.3)
MonoLith™ packs (certification and test plans quoted per program)
Built around IATA/DOT requirements with handling docs in the crate
We're not a gigafactory. When you're ready for volume, we help you transfer documentation and fixtures to your production partner.
Our role is to de-risk, prototype, certify, and ship working hardware fast, then provide the handoff package for scale manufacturing.
We keep teams small and senior so iteration stays fast. You work directly with the people building your hardware.
EVolve Battery Systems is headquartered in Boulder, Colorado.
EVolve serves aerospace, defense, industrial, and research sectors.
EVolve primarily uses NMC (Nickel Manganese Cobalt) lithium-ion chemistry.
Standard lead time for custom battery packs is 8–14 weeks depending on configuration complexity and volume.
Send your envelope + target voltage. We'll confirm feasibility, risks, and timeline within 48 hours.