Flat Pack
Skateboard
How Lithium Block™ modules enabled rapid prototyping for an electric skateboard startup's innovative flat pack design.
Project Overview
A California-based startup approached EVolve with an ambitious vision: create the world's thinnest electric skateboard by integrating the battery directly into the deck structure. Traditional cylindrical battery packs were too bulky, and custom solutions would take too long for their investor timeline.
Technical Specifications
Challenges & Solutions
Space Constraints
Skateboard deck integration required ultra-compact form factor while maintaining safety clearances.
Solution
Lithium Block™ modular design allowed precise fit within deck cavity.
Impact Resistance
Skateboard applications demand high vibration and impact tolerance.
Solution
Wire-bond compliance and reinforced enclosure design absorbed mechanical stress.
Power Delivery
Required high burst power for acceleration while maintaining range.
Solution
6P configuration provided optimal power-to-energy ratio for urban mobility.
Fast Integration
Startup needed rapid prototyping to meet investor milestones.
Solution
Pre-engineered module reduced integration time from months to weeks.
Project Timeline
Requirements Analysis
Initial consultation and technical feasibility assessment
Module Selection
Lithium Block™ 6P configuration chosen for optimal power-to-size ratio
Integration Design
Mechanical integration and thermal management planning
Prototype Delivery
Working prototype delivered with full documentation
Testing & Validation
Performance testing and safety validation completed
Results & Outcomes
The flat pack skateboard project demonstrated how pre-engineered modules can accelerate innovation in emerging mobility markets. The startup successfully raised Series A funding based on the working prototype.
Key Metrics
Technical Implementation
Module Integration
Lithium Block™ 6P module provided optimal energy density while fitting within the skateboard deck's 15mm height constraint.
Safety Design
Wire-bond fusing behavior and integrated thermal monitoring provided multiple layers of protection for consumer use.
Rapid Prototyping
Pre-engineered modules eliminated months of custom battery development, allowing focus on mechanical integration.
Lessons Learned
"Working with EVolve's pre-engineered modules allowed us to focus on what we do best (innovative mechanical design and user experience) while leveraging proven battery technology."
Lead Engineer, Urban Mobility Startup
(Name withheld for confidentiality)
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