U.S.-Engineered Battery Systems. Built to Spec.
Custom lithium-ion battery systems engineered and assembled at a single facility in Boulder, Colorado, USA. Modular platforms from 3.6 V nominal to 1,000 Vdc maximum system voltage.
Government & Contract Credentials
Company Overview
EVolve Battery Systems (EBS) designs and manufactures lithium-ion battery packs and modules for aerospace, defense, marine, industrial, and robotics programs. All engineering and assembly is performed in-house at one facility in Boulder, Colorado, with no offshore subcontracting of core manufacturing. The company has operated for over 15 years and supports programs from single evaluation units through low-to-medium-volume production, with a minimum order quantity of 1.
EBS operates two product platforms — MonoLith™ turnkey systems and Lithium Block™ wire-bonded modules — plus a bespoke engineering service for requirements outside the standard catalog. Standard MonoLith configurations ship in 8–14 weeks ARO; custom builds run 14–18 weeks depending on scope.
Leadership
Justin Dunn
Founder & President
Justin Dunn founded EVolve Battery Systems in 2013 and directs product strategy, program intake, and manufacturing operations.
linkedin.com/in/justindunn1Core Competencies
End-to-end battery system engineering — from cell selection through certified, documented hardware delivery.
Wire-Bonded Cell Interconnection
Wire-bonded cell interconnection in 18650 and 21700 cylindrical formats, providing per-cell fusing at the bond and eliminating spot-weld nickel strip failure modes.
High-Voltage System Architecture to 1,000 Vdc
Dual main contactors with precharge and controlled bleed, HVIL interlock, continuous isolation monitoring, coordinated fusing from cell to string to main, and service disconnect.
Battery Management Systems
Digital BMS monitoring all cell voltages and system temperatures, VCU compatible; CAN 2.0B interface with documented message IDs, update rates, heartbeat, and fault frames, delivered with DBC file.
Thermal Management
Aluminum frame and heat-spreader baseline with forced-air, conduction-to-cold-plate, and liquid cold plate options sized to ambient, altitude, and duty cycle.
Electrical Interfaces
Amphenol SurLok Plus high-voltage connections and Deutsch DTM signal connectors as standard; alternate interfaces specified per program ICD.
Documentation & Traceability
Interface control document, dimensional STEP CAD, CAN DBC, serialized build records, acceptance test reports, and certificates of compliance delivered with every shipment.
Product Platforms
Configurable, qualified platforms that accelerate delivery timelines — not one-off custom builds from scratch.
MonoLith™
Turnkey Battery System
Complete, integration-ready systems built from wire-bonded 21700 cells in 24-cell holders, configurable in 1S, 2S, 3S, or 4S bonding arrangements. The standard catalog spans 28.8 V to 856.8 V nominal, 3.5 to 198 kWh, and discharge power to 692 kW; bespoke configurations extend from a 3.6 V nominal floor up to the 1,000 Vdc system maximum. Enclosures are 6061-T6 aluminum with configurable dimensions. Cells are UN 38.3 certified.
Lithium Block™
Wire-Bonded OEM Module
Standalone wire-bonded 18650 modules certified to UN 38.3 at the module level and supplied to OEMs for integration into their own systems. Modules are built as 1S × P parallel arrays with voltage and temperature sense brought out through the connector, series-stackable to 500 Vdc, housed in UL94 V-0 rated material, with bracket array hardware available for multi-module packaging.
PackForge™
Configuration Platform
Online configurator covering 4,900+ addressable MonoLith system configurations, composed from 622 base packs in 1–8 parallel strings. Users filter by nominal voltage, energy, discharge power, and mass, or upload a requirements datasheet for automated spec extraction and scored matching against the full catalog. No NRE and no custom tooling on catalog configurations.
Custom Engineering & Design
Bespoke Pack Development
Application-specific pack development from requirements definition through pilot build: enclosure and envelope design, harnessing, contactor logic, fusing coordination, sensing, EMI and bleed strategy, and BMS integration with program-specific profiles. Development follows a concept → design → prototype → pilot sequence with DFMEA/PFMEA, test planning, and compliance mapping deliverables at each gate.
Differentiators
Single-site U.S. manufacturing
Engineering and assembly under one roof in Boulder, CO — direct access to the engineers who design and build the hardware, with a 15+ year operating history.
Prototype through production
MOQ of 1 for evaluation and development units, scaling to repeatable low-to-medium-volume OEM builds on the same validated platform.
Platform architecture
Shared subcomponents across the 622-pack catalog reduce NPI risk, shorten qualification, and keep spares and BOMs consistent across a fleet.
Complete data package
ICD, STEP CAD, CAN DBC, serialized build record, acceptance test report, and certificate of compliance ship with every unit — no black-box deliveries.
Compliance & Qualification
MonoLith cells and standalone Lithium Block modules are UN 38.3 certified, and all shipments include UN 38.3 hazmat documentation and compliant packaging via certified carriers. System-level qualification is scoped per program: EBS designs to and tests against customer-specified standards, delivering acceptance test procedures and reports under contract. A 1-year warranty on materials and workmanship applies, with extended terms available for production deployments.
Company Data
- Legal NameEVolve Battery Systems
- Established2013
- FounderJustin Dunn, President
- OwnershipPrivately held, U.S. owned and operated
- CAGE Code7Q5F7
- UEICKLQF1LHJ3F7
- NAICS335910 — Battery Manufacturing
- Facility6880 Winchester Circle, Unit F
Boulder, CO 80301 USA - Phone+1 (720) 414-5502
- Email[email protected]
- Webevolvebattery.us
Markets Served
- Aerospace & UAS
- Defense & UGV
- Marine & UUV
- Industrial automation
- Robotics & AGV
- Research & government labs
Response
- RFQ Response<48 hours, engineering-reviewed
- Standard Lead Time8–14 weeks ARO
- Custom Builds14–18 weeks
- Minimum Order1 unit
Industries Served
Aerospace
eVTOL, UAV propulsion, satellite power, APU replacement
Defense & Military
UGV/UUV power, directed energy, silent watch, tactical systems
Industrial
Material handling, marine propulsion, field-deployable equipment
Research & Development
National labs, university test programs, prototype validation
Past Performance
600 V pack prototype for a flight-test lab. Envelope-constrained design with FR-4 creepage per IEC, shipped with UN 38.3 handling documentation.
High-pulse UGV module with copper busbar and thermal spreader upgrade. Peak current increased 32% within the same mechanical footprint.
Dakar Rally battery system for an electric racing prototype. Multi-pack architecture designed for extreme shock and vibration environments.
Intellectual Property
MonoLith™ architecture is patent pending: U.S. Patent Application No. 18/814,733 (Pub. No. US 2025/0070315 A1), Canadian Patent Application No. 3,253,125. Filed under the company's former name, CIE Solutions LLC.
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