EVolve Battery Systems manufactures lithium-ion battery systems for aerospace applications including unmanned aerial vehicles (UAVs), eVTOL development platforms, satellite ground support equipment, high-altitude pseudo-satellites (HAPS), and experimental aircraft. Systems are built on NMC (nickel manganese cobalt) chemistry, which offers higher energy density than LFP, a critical advantage when weight and volume are constrained. Nominal voltage configurations span 28V to 400V, with capacity from 0.5 kWh to 50+ kWh in single-pack form. EVolve designs with aerospace environmental categories in mind and can support programs pursuing DO-160 environmental qualification. Wire-bonded cell interconnection eliminates welded tabs, providing cell-level fault tolerance without a thermal propagation path through the interconnect. All hardware is manufactured at EVolve's facility in Boulder, Colorado, USA.
Development and flight test articles for MALE, tactical, and VTOL UAS platforms. Structural enclosures designed for the shock and vibration profiles of airborne programs. Defined interfaces from day one.
Development-phase packs for eVTOL programs and electric auxiliary power units (e-APU). High continuous and peak discharge rates support propulsion and hover power profiles.
Flight test and development hardware for electric propulsion programs in pre-certification phases. 18-month lead times of volume aerospace suppliers are bypassed with EVolve's prototype path.
High-power DC supply for flight simulation, propulsion test stands, and lab load emulators. Dual contactors with precharge, HVIL, isolation monitoring, and CAN telemetry.
Mission-critical backup power for hypersonic and advanced propulsion development vehicles. EVolve has delivered an 8.8 kWh, 403V system for a hypersonic propulsion program.
View program →Power storage for satellite test facilities and ground support equipment requiring precise voltage stability and long-duration discharge capability.
All EVolve battery systems are shipped with UN38.3 transport classification, which is required for air freight and hazmat shipping documentation. This covers transportation safety; it is not a system-level airworthiness certification.
For program-level environmental qualification, EVolve designs battery systems with DO-160 environmental categories in mind. DO-160 covers temperature, altitude, vibration, shock, humidity, EMI, and other environmental conditions relevant to airborne equipment. EVolve can support testing to DO-160 sections at qualified test laboratories and can provide the documentation package (test plans, test reports, compliance matrix) needed for program qualification. EVolve does not currently hold a DO-160 certification on any standard product; qualification is executed per-program.
NMC chemistry provides higher gravimetric energy density (typically 180–250 Wh/kg at cell level) compared to LFP (150–180 Wh/kg), which is a meaningful advantage in weight-constrained aerospace applications. At the system level, wire-bonded interconnection eliminates the mass of tab welds and busbars, and aluminum 6061-T6 enclosures provide structural rigidity at lower weight than steel alternatives.
For programs with extreme weight budgets, EVolve can discuss reduced-mass enclosure designs, optimized module configurations, and cell selection tradeoffs. Lightweight does not always mean lower structural protection; EVolve engineering reviews vibration and shock environments before finalizing enclosure design.
The most common aerospace voltage configurations are in the 28V–400V range, which aligns with aircraft bus standards (28V DC, 270V DC, 540V DC) and propulsion inverter input requirements. EVolve configures MonoLith voltage in 7.2V steps, allowing precise matching to required bus voltages.
| Application | Typical Voltage | Typical Capacity |
|---|---|---|
| Small UAV (tactical) | 28V – 50V | 0.5 – 5 kWh |
| MALE UAS | 50V – 150V | 5 – 30 kWh |
| eVTOL propulsion | 300V – 400V | 20 – 80 kWh |
| Electric propulsion test | 100V – 400V | 10 – 50 kWh |
| Ground support / lab | 48V – 200V | 5 – 30 kWh |
Use PackForge™ to filter configurations by your target voltage and capacity range.
Standard MonoLith systems include a custom BMS, which provides cell-level voltage and temperature monitoring, active cell balancing, state-of-charge (SOC) and state-of-health (SOH) estimation, programmable fault thresholds, and CAN bus telemetry. Safety architecture includes:
Wire-bonded interconnection adds a passive safety layer: if a cell fails or shorts, the aluminum wire bonds at that cell open before significant current flows, isolating the faulty cell without thermal propagation through a welded tab.
EVolve enclosures are machined or fabricated from 6061-T6 aluminum, which provides high stiffness-to-weight ratio and resistance to fatigue under cyclic vibration. Module mounting uses constrained elastomeric elements or direct rigid mounting depending on the vibration spectrum of the target platform. All internal cell arrays are bonded with structural adhesive to prevent relative motion.
For programs with defined vibration and shock requirements (DO-160, MIL-STD-810, or customer-defined profiles), EVolve reviews the applicable spectra during the design phase and can specify mounting isolation, enclosure wall thickness, and internal bracing accordingly. Qualification testing at third-party vibration test facilities can be scoped as part of the program.
EVolve has delivered flight test articles that survived sustained shock and vibration environments on tactical UAS and rally racing platforms. See the Dakar Rally Battery program for an example of a 773V system qualified for high-vibration environments.
Submit voltage, capacity, envelope, interface, and environmental requirements via RFQ or PackForge. Include any existing CAD envelope or reference drawing.
EVolve engineering reviews for in-catalog fit and flags constraints within 2–5 business days. On contract: STEP CAD, ICD, CAN DBC, and LV harness pinout.
First-article hardware in 8–16 weeks from contract. Full documentation package included. Integration begins from a known baseline.