EVolve Battery Systems

Capabilities Brief

Lithium-ion battery systems for teams that need working hardware fast

Who We Are

EVolve designs and builds lithium-ion battery systems for teams that need working hardware fast—and can't afford black-box surprises. We ship configurable COTS building blocks and engineer custom packs for aerospace, defense, motorsport, and industrial use. Low-volume today, scaling deliberately. No fluff.

What We Do

COTS Modules — Lithium Block™ Gen2

5P–10P, Energy and Power variants; wire-bonded 21700 NMC cells; designed for series stacking and rapid pack assembly.

Pack Platforms — MonoLith™

Structural, liquid-cooled arrays with serviceable manifolds, tunable flow paths, HVIL, pre-charge, contactors, and integrated PDU options.

Custom Packs & PDUs

Application-specific packaging, harnessing, contactor logic, fusing, sensing, and EMI/bleed strategies; full BMS integration with custom profiles.

Engineering Services

Concept → design → prototype → pilot build; DFMEA/PFMEA, test planning, compliance mapping, and documentation.

FSAE & Research Support

Rule-compliant segmentation (≤100 V per segment), clear manuals, and a buy-back path for refurb/resale.

How We Build

Cells & Interconnects

21700 NMC; aluminum/copper bus, FR-4 power PCBs, and wire-bonded joints for low impedance and graceful degradation.

Thermal System

Structural liquid manifold; per-array flow tuning to keep ΔT tight; designed for fast purge/bleed and field service. Each coolant loop is nitrogen pressure-held ≥24 hrs pre-ship to confirm leak integrity.

Electrical Safety

Segmented arrays, HVIL, contactor logic with pre-charge, coordinated fusing, touch-safe internals (IP2X min).

Enclosure & IP Rating

Design targets IP67 with gasketed interfaces and venting options; build-specific IP54–IP67 available. Formal third-party certification can be scoped when required.

Battery Management System

White-labeled tier-one BMS options with custom profiles, balancing strategies, and telemetry hooks; we can own profile development to your specification.

PDU Integration

HV distribution, fusing, bleed, discharge, service loops, and test points, packaged for your installation envelope.

Compliance & Testing

Standard/Test	Current Status	Notes
UN38.3 Shipping	Certified	Lithium Block 5P, 6P, and 10P (Energy and Power variants)
Shipping & Regulations	Compliant	IATA SP310 and DOT §173.185 aligned packaging and paperwork
Design Rules	Applied	Clearance/creepage per IEC 60664 guidance; PCBs per IPC-4101/6012
Environmental/EMC	Program-Specific	Test plans align to program needs (e.g., DO-160-aligned where applicable)
Quality Records	Standard	Isolation tests, leak checks, and pack-level functional verification with serial traceability

Where We Fit

R&D & Prototypes

Weeks to first articles using COTS modules and the pack platform; iterate on measured data.

Pilot/Short-Series

Tens to low hundreds of units with consistent build records and service plans.

Design-to-Specification

You bring the envelope and requirements; we own architecture, verification, and manufacturability.

Co-Development

Shared roadmap and licensing where platform reuse makes economic sense.

Markets Served

Aerospace prototypes & flight demonstrators, defense UGV/UAS, motorsport (FSAE/EV), specialty vehicle, robotics, industrial equipment, and lab/field power systems.

Why Teams Choose EVolve

Speed without guesswork: COTS modules + repeatable pack patterns shrink calendar risk
Serviceable thermal hardware: Manifolds add stiffness, protect lines, and keep ΔT uniform as arrays scale
Transparent engineering: Open documentation, test evidence, and honest limits
Scale with intent: We help you de-risk the first 10–100 and plan the path beyond
Lifecycle support: Refurb, buy-back (FSAE), and data-backed upgrades instead of dead-end hardware

Track Record

Delivered hundreds of Lithium Block modules and initial MonoLith packs; active in FSAE and aerospace prototyping.

Teams we've engaged with include programs at NASA/JPL, Hermeus, Blue Origin, Tesla and university racing—primarily prototypes and evaluation units, not high-volume supply.

Typical Deliverables

Design

Requirements brief
Architecture options
Thermal/electrical stack-up
CAD packages

Analysis

Current density and thermal modeling
Fuse/contactor coordination
Isolation paths

Testing

UN38.3 plans/results (where applicable)
Isolation & dielectric withstand
Leak/pressure logs
Functional checks

Documentation

Manufacturing travelers & QC checklists
Installation/ops/maintenance manuals
Hazard and transport guides
BMS configs and calibration files

How to Engage

Scope Call

45–60 minute discussion: use-case, constraints, success criteria.

Rapid Brief

3–5 page technical brief: architecture, risks, ROM budget/schedule.

NRE & First Articles

Design + prototype with defined test gates.

Pilot Build

Short-series with documentation, spares, and service plan.

Scale Decision

Validate performance/ops data and choose the path forward.

Technical Specifications

Wire-bonded 21700 NMC architecture, Energy/Power module families (5P–10P)
Structural liquid-cooling with tunable flow and fast purge/bleed
HVIL, pre-charge, contactors, coordinated fusing, touch-safe internals
UN38.3 certified variants: Lithium Block 5P/6P/10P (Energy & Power)
Build-specific IP54–IP67; nitrogen leak hold ≥24 hrs per loop pre-ship
White-labeled BMS with custom profiles and full PDU integration
Documentation that travels: install/ops/service + test evidence

Boundaries

We are not a commodity cell reseller or a high-volume contract manufacturer—yet.
Our COTS packs are not pre-certified to every industry standard. If you need formal certifications (IP67 unit-level, DO-160, MIL-STD, etc.), we'll scope and execute with you.
Lead times and costs reflect real engineering and test, not wishful thinking.

Contact Information

Ready to discuss your battery system requirements?

Website

evolvebattery.us

Email

info@evolvebattery.us

Phone

+1 720-414-5502

Location

Colorado, USA