EVolve Battery Systems designs and manufactures custom lithium-ion battery packs at its facility in Boulder, Colorado, USA. The company produces NMC (nickel manganese cobalt) chemistry packs using wire-bonded cell interconnection architecture, covering voltage ranges from 14.4V to 460.8V and capacities from 0.5 kWh to 300+ kWh per system. Multi-pack configurations scale beyond these bounds. The MonoLith product line supports over 500 discrete configurations accessible through the PackForge™ configurator, spanning applications in aerospace, defense, industrial automation, robotics, marine, and research. All engineering and assembly is performed in-house in Boulder, with no offshore subcontracting of core manufacturing. Minimum order quantity is one unit. EVolve ships to customers across the United States and internationally to qualified programs.
EVolve produces two primary product lines, which address different program requirements:
The MonoLith is a complete, integration-ready battery pack built around wire-bonded Lithium Block modules. Voltage range: 14.4V to 460.8V nominal (configurable in 7.2V steps via series module count). Capacity range: 0.5 kWh to 300+ kWh in single-pack configuration, scalable further through multi-pack parallel strings. Standard enclosures are 6061-T6 aluminum with configurable dimensions; custom envelope sizing is available on contract. Every MonoLith ships with an integrated custom BMS, dual main contactors with precharge, HVIL, isolation monitoring, CAN bus communication, thermal management provisions, and a full interface control document (ICD) covering connector pinouts, CAN DBC, and dimensional STEP CAD.
The Lithium Block is a self-contained wire-bonded module used as the building block inside MonoLith systems and as a standalone component for OEM integration. Each module contains prismatic or cylindrical cells interconnected via aluminum or gold wire bonding, which eliminates tab welding and provides fault-tolerant cell-level disconnection if any bond fails. Housing is aluminum. Modules are available in multiple energy configurations covering the 0.3–2.5 kWh per module range. UN38.3 transport classification applies to all shipped modules.
Customization is addressed through a fit-check process before contract execution. The following parameters are configurable:
PackForge™ is EVolve's interactive battery configuration tool for MonoLith products. It presents the full catalog of available configurations filterable by application type, voltage range, energy range, and mechanical constraints. Each configuration card shows nominal voltage, capacity, peak and continuous power, dimensions, estimated weight, and available cooling options. Spec sheets are downloadable directly from configurator results. RFQ submission is integrated: prospective customers can submit application requirements, upload reference CAD or envelope constraints, and initiate the fit-check process without a prior call.
PackForge covers 500+ discrete MonoLith configurations. For applications outside the standard catalog, including unusual voltages, extreme temperature environments, non-standard form factors, or defense/aerospace programs with unique interface requirements, the RFQ path routes to engineering review rather than automated configuration.
UAV/UAS prototypes, eVTOL development, flight test articles, electric propulsion. Voltage range 28V–400V most common; structural aluminum enclosures rated for airborne vibration environments.
UGV/UUV propulsion, directed energy support, ISR platforms, forward operating base power. Full ICD on contract; ITAR-compatible domestic manufacturing.
AGV/AMR fleets, warehouse automation, outdoor autonomous platforms, test stand power, controls backup. Duty cycle and charge/discharge profile matched to application.
Electric propulsion, hybrid marine power, autonomous surface vessels. Higher-capacity configurations (25 kWh+); IP-rated enclosures available.
Prototype and development programs, FSAE motorsport, national lab applications. Single-unit MOQ; traceable assembly; documentation suitable for academic and government programs.
Skateboard platforms, Class 3 delivery vans, specialty vehicles. Modular skateboard architecture with defined busbar geometry and connector pinouts.
The order process begins with a fit-check. Customers submit voltage, capacity, envelope, interface, and application requirements via RFQ or through PackForge. EVolve engineering reviews for in-catalog fit or flags constraints within 2–5 business days.
Minimum order quantity is one unit. No catalog minimum. Volume pricing is available for qualified recurring programs.
EVolve Battery Systems is headquartered and manufactures in Boulder, Colorado, USA. All engineering, assembly, testing, and documentation are performed in-house at this facility. There is no offshore subcontracting of core manufacturing.
Domestic manufacturing in Boulder provides several practical advantages for U.S. customers:
Phone: +1-720-414-5502 · Boulder, Colorado, United States