EVolve Battery Systems designs and manufactures lithium-ion battery systems for defense and military applications at its facility in Boulder, Colorado, USA. All engineering and assembly are performed domestically, with no offshore subcontracting of core manufacturing. Systems are built on NMC chemistry in 6061-T6 aluminum enclosures, with voltage configurations from 24V to 460V and capacity from 1 kWh to 300+ kWh per system. Defense application types include unmanned ground vehicles (UGVs), unmanned underwater vehicles (UUVs), soldier-portable power, directed energy support, forward operating base (FOB) power, communications and ISR platform power, and high-power vehicle platforms. EVolve has delivered battery systems to programs with U.S. Army DEVCOM GVSC and to advanced propulsion development programs in the aerospace and defense sectors.
High-voltage drive systems for unmanned ground vehicles. Defined CAN interface, full ICD, and STEP CAD on contract for seamless integration with drive controllers and vehicle management systems.
Underwater unmanned vehicle battery packs designed for the pressure, temperature, and sealing requirements of submerged operation. Aluminum enclosures with custom sealing strategies available.
High-power pulsed discharge capability for directed energy payloads. Peak power delivery exceeding 350 kW on applicable configurations. Discharge profile can be matched to the weapon system's energy storage requirements.
Lower-voltage configurations (24V–48V) for portable soldier power, dismounted electronics, and forward-deployed computing. Compact, lightweight designs with ruggedized connectors.
Extended silent watch capability for vehicle-borne systems. Defined discharge profiles for sustained low-current draw with peak availability for burst loads.
Power for ISR sensor payloads, radar systems, communications equipment, and electronic warfare platforms. CAN telemetry enables integration with platform power management systems.
See the Series-Hybrid Rescue Vehicle program, a 19 kWh, 420V MonoLith system delivered for a semi-autonomous platform developed with U.S. Army DEVCOM GVSC.
EVolve Battery Systems manufactures all products domestically at its Boulder, Colorado facility. Engineering, assembly, test, and documentation are performed in-house with no offshore manufacturing subcontracting. EVolve can discuss ITAR program requirements during the RFQ process and can accommodate domestic-manufacturing requirements for defense programs.
Colorado's proximity to major defense programs, national laboratories, and government facilities provides logistics and collaboration advantages for U.S. government customers. EVolve engineering staff can travel to customer facilities for design reviews, first-article testing, and integration support.
Standard MonoLith enclosures are machined 6061-T6 aluminum, which provides high stiffness-to-weight ratio, resistance to impact and vibration, and compatibility with standard EMI/RFI gaskets. Additional ruggedization options include:
EVolve designs battery systems with MIL-STD requirements in mind and can support qualification testing to these standards. Current awareness and design practice includes:
| Standard | Scope | EVolve Posture |
|---|---|---|
| MIL-STD-810 | Environmental testing: temperature, vibration, shock, humidity, altitude | Designed with awareness; can support test campaign at qualified lab |
| MIL-STD-1275 | Vehicle electrical power characteristics (28V military vehicles) | Input/output interface compatibility; relevant for vehicle integration |
| MIL-STD-461 | EMI/EMC emissions and susceptibility | Enclosure designed for shielding; EMC test campaign supportable per program |
Defense programs often require detailed traceability for supply chain security and qualification. EVolve standard delivery documentation includes:
Defense applications span a wide range of voltage and capacity requirements depending on platform type:
| Platform Type | Typical Voltage | Typical Capacity |
|---|---|---|
| Soldier-portable / dismounted | 24V – 48V | 0.5 – 3 kWh |
| Small UGV / robotic platform | 48V – 96V | 3 – 15 kWh |
| Tactical vehicle (light) | 96V – 200V | 15 – 50 kWh |
| Heavy vehicle / DE support | 200V – 460V | 50 – 300+ kWh |
| UUV (underwater) | 48V – 200V | 5 – 50 kWh |
Submit voltage, capacity, envelope, interface, thermal, and environmental requirements. Mention program classification level and any specific domestic manufacturing or ITAR requirements.
Engineering reviews within 2–5 business days. On contract: STEP CAD, ICD, CAN DBC, LV harness pinout, and initial safety analysis.
First-article delivery in 8–16 weeks from contract. Full documentation package. NDA available for discussing confidential program details.