{ "settings": { "legalName": "EV Battery Solutions", "footerYear": "2026", "showTeam": false, "companyName": "EV Battery Solutions", "tagline": "Precision Energy. Engineered in Bengaluru.", "founded": "2016", "location": "Indiranagar, Bengaluru", "phone": "+91 78923 57850", "phoneTech": "", "whatsapp": "917892357850", "email": "bharath@evbatterysolutions.com", "emailSupport": "", "emailCareers": "", "registeredAddress": "#409, 1st Cross, 1st Stage Indiranagar, Bengaluru - 560038", "workshopAddress": "#49, 1st Cross, 1st Stage Indiranagar, Bengaluru - 560038", "address": "EV Battery Solutions Workshop: #49, 1st Cross, 1st Stage Indiranagar, Bengaluru - 560038.", "hours": "Mon - Fri: 9 AM - 6 PM | Sat & Sun: Closed", "instagram": "https://www.instagram.com/ev_battery_solutions", "linkedin": "https://www.linkedin.com/company/ev-battery-solutions", "twitter": "", "youtube": "https://www.youtube.com/@evbatterysolutions", "heroTitle": "Precision Energy.", "heroTitleAccent": "Engineered Here.", "heroDesc": "Custom battery packs for EVs, BESS, UAVs, robotics, medical and industrial applications. Design, development and manufacturing — all under one roof.", "heroBadge": "🇮🇳 Bengaluru, India", "stats": [ { "value": 15000, "suffix": "+", "label": "Packs Assembled / Built" }, { "value": 2000, "suffix": "+", "label": "Projects Delivered" }, { "value": 8, "suffix": "+", "label": "Years of Expertise" }, { "value": 25, "suffix": "+", "label": "Industries Served" } ], "certifications": [ "IEC 62133", "UN 38.3", "AIS-156", "BIS Registration", "MSME Udyam Reg." ], "missionTitle": "To make precision battery engineering accessible to every Indian innovator.", "missionDesc": "Whether you are an EV startup, a defence contractor, a hobbyist maker or a Fortune 500 company — we bring the same engineering rigour to every project, at every scale.", "visionTitle": "To be India's most trusted battery pack engineering partner by 2030.", "visionDesc": "Driving India's energy transition — from fossil to electric — by building reliable, safety-tested and cost-competitive battery systems that power the next generation of mobility and storage.", "facilityTitle": "Battery workshop in Indiranagar", "facilityDesc": "Our workshop at #49, 1st Cross, 1st Stage Indiranagar, Bengaluru is where battery pack design, assembly, BMS integration, diagnostics and service work are coordinated for EV, BESS, UAV, robotics and industrial projects.", "facilityImage": "" }, "products": [ { "id": 1, "name": "EVBS-4850 LFP", "cat": "EV", "chem": "LFP", "voltage": 48, "capacity": 50, "price": "₹28,000", "weight": "8.2 kg", "cycles": 3000, "ip": "IP67", "bms": true, "tags": [ "2W EV", "3W EV", "Solar" ], "desc": "Compact LFP pack designed for electric two and three-wheelers. Robust BMS with cell balancing and over-temp protection." }, { "id": 2, "name": "EVBS-7260 NMC", "cat": "EV", "chem": "NMC", "voltage": 72, "capacity": 60, "price": "₹52,000", "weight": "10.4 kg", "cycles": 1500, "ip": "IP65", "bms": true, "tags": [ "4W EV", "e-Loader" ], "desc": "High energy density NMC pack for passenger EVs. Integrated thermal management and CAN bus communication." }, { "id": 3, "name": "EVBS-9680 LFP", "cat": "EV", "chem": "LFP", "voltage": 96, "capacity": 80, "price": "₹78,000", "weight": "14.6 kg", "cycles": 3000, "ip": "IP67", "bms": true, "tags": [ "Commercial EV", "Bus" ], "desc": "Heavy-duty pack for commercial electric vehicles and e-buses. Modular design for easy cell replacement." }, { "id": 4, "name": "BESS-4820", "cat": "BESS", "chem": "LFP", "voltage": 48, "capacity": 200, "price": "₹1,20,000", "weight": "42 kg", "cycles": 6000, "ip": "IP55", "bms": true, "tags": [ "Solar", "Home Storage" ], "desc": "Rack-mount BESS unit for solar + storage systems. RS485/Modbus interface for inverter integration." }, { "id": 5, "name": "BESS-5120", "cat": "BESS", "chem": "LFP", "voltage": 51.2, "capacity": 100, "price": "₹85,000", "weight": "28 kg", "cycles": 6000, "ip": "IP55", "bms": true, "tags": [ "Commercial", "Telecom" ], "desc": "Telecom-grade LFP storage system. Supports parallel stacking up to 8 units for scalable capacity." }, { "id": 6, "name": "UAV-6S-12", "cat": "UAV", "chem": "NMC", "voltage": 22.2, "capacity": 12, "price": "₹8,500", "weight": "0.62 kg", "cycles": 300, "ip": "None", "bms": true, "tags": [ "Racing Drone", "Survey" ], "desc": "Ultra-light 6S drone pack. 45C continuous discharge, heat-shrink wrapped, XT60 connector." }, { "id": 7, "name": "UAV-12S-22", "cat": "UAV", "chem": "NMC", "voltage": 44.4, "capacity": 22, "price": "₹18,000", "weight": "1.4 kg", "cycles": 400, "ip": "None", "bms": true, "tags": [ "Heavy Lift", "Agri Drone" ], "desc": "High-capacity agricultural and payload drone pack. Smart BMS with remaining flight time estimation." }, { "id": 8, "name": "AGV-2460", "cat": "AGV", "chem": "LFP", "voltage": 24, "capacity": 60, "price": "₹22,000", "weight": "7.8 kg", "cycles": 3000, "ip": "IP54", "bms": true, "tags": [ "AGV", "Forklift", "AMR" ], "desc": "Reliable LFP pack for autonomous guided vehicles. Fast-charge compatible, hot-swap ready design." }, { "id": 9, "name": "ROB-1220", "cat": "Robotics", "chem": "NMC", "voltage": 12, "capacity": 20, "price": "₹6,500", "weight": "0.9 kg", "cycles": 800, "ip": "IP44", "bms": true, "tags": [ "Cobots", "Service Robot" ], "desc": "Compact NMC pack for collaborative and service robots. Low internal resistance for peak torque delivery." }, { "id": 10, "name": "MED-2410", "cat": "Medical", "chem": "LFP", "voltage": 24, "capacity": 10, "price": "₹14,000", "weight": "1.8 kg", "cycles": 2000, "ip": "IP44", "bms": true, "tags": [ "Ventilator", "Infusion", "Portable" ], "desc": "IEC 62133 certified medical-grade pack. Dual BMS redundancy, UL flame-retardant enclosure." }, { "id": 11, "name": "IND-4830", "cat": "Industrial", "chem": "LFP", "voltage": 48, "capacity": 30, "price": "₹19,500", "weight": "6.2 kg", "cycles": 3000, "ip": "IP54", "bms": true, "tags": [ "Power Tools", "UPS", "Field" ], "desc": "Rugged industrial LFP pack. Wide operating temperature -20°C to 60°C, vibration resistant housing." }, { "id": 12, "name": "DIY-KIT-36", "cat": "DIY", "chem": "LFP", "voltage": 36, "capacity": 20, "price": "₹4,200", "weight": "3.1 kg", "cycles": 2000, "ip": "None", "bms": false, "tags": [ "DIY", "E-Bike", "Maker" ], "desc": "DIY LFP cell kit with spot-welding tabs, nickel strips, and wiring harness. BMS sold separately." } ], "services": [ { "id": 1, "key": "serviceCustomPacks", "icon": "🔋", "title": "Custom Lithium Battery Pack Solutions", "color": "blue", "desc": "Fully custom lithium battery packs from 12V to 750V for EVs, drones, robotics, AGVs, medical equipment, industrial systems and storage projects.", "features": [ "Cell chemistry selection", "Series/parallel pack architecture", "Mechanical enclosure design", "Smart BMS and charger matching", "Pack-level validation report" ], "deliverables": [ "Pack specification", "Cell and chemistry recommendation", "BMS and charger recommendation", "Mechanical enclosure review", "Validation checklist" ], "timeline": "1 - 3 weeks for design scope", "from": "", "path": "/services/custom-lithium-battery-packs-solutions", "seoTitle": "Custom Lithium Battery Pack Solutions in Bengaluru | EVBS", "seoDescription": "Custom lithium battery pack design and manufacturing in Bengaluru for EV, drone, robotics, AGV, medical, industrial and BESS applications.", "keywords": "custom lithium battery pack Bengaluru, custom battery pack India, EV battery pack design, lithium ion battery pack manufacturer Bangalore", "applications": [ "Electric 2W and 3W", "Drones and UAVs", "Robotics and AGV", "Medical devices", "Industrial and BESS" ] }, { "id": 2, "key": "serviceBms", "icon": "💡", "title": "Battery Management System (BMS)", "color": "cyan", "desc": "Smart BMS selection, wiring, firmware coordination, SOC/SOH estimation, balancing and CAN, RS485, Modbus, UART or Bluetooth communication support.", "features": [ "BMS current sizing", "Cell balancing strategy", "Protection settings", "Communication protocol mapping", "Fault diagnosis workflow" ], "deliverables": [ "BMS sizing note", "Wiring and sensor review", "Communication protocol mapping", "Protection settings review", "Fault diagnosis summary" ], "timeline": "3 - 10 working days after pack review", "from": "", "path": "/services/battery-management-system-bms", "seoTitle": "Battery Management System BMS Services | Bengaluru EVBS", "seoDescription": "BMS development, integration, wiring, communication and diagnostics for lithium battery packs, EVs, BESS, robotics and industrial systems.", "keywords": "BMS development Bengaluru, battery management system India, smart BMS integration, CAN BMS, RS485 BMS, lithium battery BMS", "applications": [ "EV battery packs", "BESS and inverter packs", "Fleet telemetry", "Robotics and AGV", "Industrial battery systems" ] }, { "id": 3, "key": "serviceCharging", "icon": "⚡", "title": "Lithium Battery Charging Solutions", "color": "blue", "desc": "Battery charger selection, charging profile matching, connector polarity, current limits and safe charge-system integration for lithium packs.", "features": [ "CC/CV profile selection", "Connector and polarity check", "Charge current recommendation", "Thermal safety limits", "Charger compatibility notes" ], "deliverables": [ "Charging profile recommendation", "Connector and polarity notes", "Charge current limits", "Charger compatibility guidance", "Usage and storage notes" ], "timeline": "2 - 7 working days after charger details", "from": "", "path": "/services/lithium-battery-charging-solutions", "seoTitle": "Lithium Battery Charging Solutions in India | EVBS", "seoDescription": "Lithium battery charger matching, charging profile selection and connector integration for EV, BESS, drone and industrial battery packs.", "keywords": "lithium battery charger India, EV battery charging solution, battery charger matching, LFP charger, NMC charger Bengaluru", "applications": [ "LFP and NMC packs", "EV scooters and rickshaws", "BESS inverter charging", "Drone charging bays", "Industrial equipment" ] }, { "id": 4, "key": "serviceManufacturing", "icon": "🏭", "title": "Battery Pack Manufacturing & Assembly", "color": "blue", "desc": "Small-batch and series battery pack manufacturing with cell grading, spot welding, BMS flashing, pack testing, traceability and packaging.", "features": [ "Cell inspection and grading", "Spot welding and busbar assembly", "BMS integration", "Capacity and IR testing", "Batch QA documentation" ], "deliverables": [ "Pilot or batch build plan", "Cell inspection and grading", "BMS integration", "Pack-level QA checks", "Batch test summary" ], "timeline": "Prototype to pilot batch after approved BOM", "from": "", "path": "/services/battery-pack-manufacturing-assembly", "seoTitle": "Battery Pack Manufacturing & Assembly Bengaluru | EVBS", "seoDescription": "Lithium battery pack manufacturing and assembly in Bengaluru for EV, BESS, UAV, robotics, medical and industrial applications.", "keywords": "battery pack manufacturing Bengaluru, lithium battery assembly India, EV battery manufacturer Bangalore, battery pack production", "applications": [ "Pilot batches", "OEM production", "BESS modules", "Drone battery packs", "Industrial packs" ] }, { "id": 5, "key": "serviceServicing", "icon": "🔧", "title": "Battery Pack Servicing & Repair", "color": "cyan", "desc": "Battery diagnosis, capacity testing, cell-group repair, BMS fault investigation, range restoration and AMC support for serviceable lithium packs.", "features": [ "Visual and safety inspection", "Voltage and imbalance diagnosis", "Controlled capacity test", "Repair scope and quote", "Post-service report" ], "deliverables": [ "Safety inspection", "Fault diagnosis", "Repair or replacement scope", "Capacity test summary where applicable", "Post-service guidance" ], "timeline": "Diagnosis first, repair timeline after inspection", "from": "", "path": "/services/battery-pack-servicing-repair", "seoTitle": "Battery Pack Repair & Servicing Bengaluru | EVBS", "seoDescription": "Lithium battery pack repair, diagnostics, capacity testing, BMS repair and cell replacement services from EV Battery Solutions Bengaluru.", "keywords": "battery pack repair Bengaluru, lithium battery repair India, EV battery service Bangalore, BMS repair, battery capacity testing", "applications": [ "EV scooter packs", "E-rickshaw packs", "Drone batteries", "Industrial packs", "BESS modules" ] }, { "id": 6, "key": "servicePrototyping", "icon": "🔬", "title": "Battery Pack Prototyping Services", "color": "cyan", "desc": "Fast, testable battery prototypes for startups, R&D teams and product builders who need fitment, performance and safety validation before production.", "features": [ "Prototype BOM", "Working battery sample", "Charge/discharge test data", "Thermal observations", "DFM improvement list" ], "deliverables": [ "Prototype BOM", "Working battery sample", "Fitment and electrical observations", "Test data summary", "DFM improvement list" ], "timeline": "2 - 4 weeks after requirements and parts availability", "from": "", "path": "/services/battery-pack-prototyping", "seoTitle": "Battery Pack Prototyping Services Bengaluru | EVBS", "seoDescription": "Battery pack prototyping in Bengaluru with cell selection, BMS integration, enclosure fitment, testing and design-for-manufacturing support.", "keywords": "battery pack prototyping Bengaluru, lithium battery prototype India, EV battery prototype, custom battery prototype", "applications": [ "Startup MVPs", "EV conversion trials", "UAV payload testing", "Robotics proof-of-concept", "Product R&D" ] }, { "id": 7, "key": "service3dPrinting", "icon": "🧩", "title": "3D Printing for Battery Enclosures & Fixtures", "color": "blue", "desc": "Functional 3D printed holders, brackets, covers, jigs, fixtures and prototype battery enclosures for EV, robotics, UAV and industrial projects.", "features": [ "CAD review", "Material recommendation", "Fitment prototype", "Iteration support", "Low-volume printed parts" ], "deliverables": [ "CAD review", "Material recommendation", "Fitment prototype", "Iteration notes", "Low-volume printed part support" ], "timeline": "2 - 10 working days based on CAD and material", "from": "", "path": "/services/3d-printing-battery-enclosures", "seoTitle": "3D Printing Battery Enclosures Bengaluru | EVBS", "seoDescription": "3D printing for battery enclosures, cell holders, brackets, jigs, fixtures and prototype parts for EV and lithium battery projects in Bengaluru.", "keywords": "3D printed battery enclosure Bengaluru, battery enclosure prototype, 3D printing for EV battery, cell holder 3D print India", "applications": [ "Battery enclosure prototypes", "Cell holders and spacers", "Connector mockups", "BMS mounts", "Jigs and test fixtures" ] }, { "id": 8, "key": "serviceTesting", "icon": "🛡️", "title": "Battery Testing & Certification Support", "color": "blue", "desc": "Electrical, mechanical and safety validation support for lithium battery packs, including pre-compliance checks and documentation guidance.", "features": [ "Capacity and IR testing", "Thermal and safety checks", "Compliance checklist", "Documentation guidance", "Test report support" ], "deliverables": [ "Capacity and IR checks", "Thermal and safety observations", "Compliance checklist", "Documentation guidance", "Test report support" ], "timeline": "Scheduled after pack readiness and test scope", "from": "", "path": "/services/battery-testing-certification-support", "seoTitle": "Battery Testing & Certification Support India | EVBS", "seoDescription": "Battery pack testing, validation and certification support for IEC, BIS, UN 38.3, AIS-156 and lithium battery safety documentation.", "keywords": "battery testing India, lithium battery certification support, AIS 156 battery testing, UN 38.3 battery, IEC 62133 battery support", "applications": [ "EV packs", "Portable lithium packs", "Export documentation", "BESS systems", "Industrial packs" ] } ], "industries": [ { "id": 1, "key": "industryElectricVehicles", "icon": "🛵", "title": "Electric Vehicle Battery Packs", "color": "blue", "clients": "EV startups, fleet operators, 2W/3W/4W OEMs", "desc": "Custom EV battery packs for electric two-wheelers, three-wheelers, commercial EVs and fleet platforms designed in Bengaluru.", "useCases": [ "Electric scooters", "Electric three-wheelers", "Fleet EV packs", "Commercial EV platforms", "EV conversion projects" ], "specs": [ "LFP / NMC chemistry selection", "Controller peak-current support", "Smart BMS and charger matching", "Vibration and weather-aware enclosure", "AIS-156 documentation support" ], "path": "/industries/electric-vehicles", "seoTitle": "Electric Vehicle Battery Packs in India | EVBS Bengaluru", "seoDescription": "Custom EV battery packs for electric two-wheelers, three-wheelers, commercial EVs and fleet platforms designed in Bengaluru.", "keywords": "EV battery pack India, electric vehicle battery pack Bengaluru, scooter battery pack, e-rickshaw battery, commercial EV battery" }, { "id": 2, "key": "industryBess", "icon": "☀️", "title": "BESS & Grid Storage Battery Packs", "color": "cyan", "clients": "Solar EPCs, telecom, commercial backup and storage integrators", "desc": "LFP battery packs and modules for solar BESS, inverter storage, telecom backup and commercial energy storage systems.", "useCases": [ "Solar energy storage", "Telecom backup", "Commercial UPS replacement", "Mini-grid storage", "Inverter-compatible LFP packs" ], "specs": [ "Long-cycle LFP chemistry", "RS485 / Modbus interface support", "Rack or cabinet layouts", "Inverter voltage-window matching", "Thermal and service access planning" ], "path": "/industries/bess-grid-storage", "seoTitle": "BESS Battery Packs & Solar Storage India | EVBS", "seoDescription": "LFP battery packs and modules for solar BESS, inverter storage, telecom backup and commercial energy storage systems.", "keywords": "BESS battery pack India, solar storage battery, LFP storage battery, commercial energy storage Bengaluru" }, { "id": 3, "key": "industryUavDrones", "icon": "🛸", "title": "UAV & Drone Battery Packs", "color": "blue", "clients": "Drone OEMs, agri drone teams, survey and defence UAV builders", "desc": "Lightweight high-discharge custom battery packs for agricultural drones, survey UAVs, delivery drones and defence aerial platforms.", "useCases": [ "Agricultural drones", "Survey UAVs", "Heavy-lift drones", "Delivery drone prototypes", "Defence aerial platforms" ], "specs": [ "High-discharge cells", "Weight-optimised pack layout", "Voltage sag review", "Payload-aware runtime sizing", "Connector and fast-charge safety" ], "path": "/industries/uav-drone-battery-packs", "seoTitle": "Drone Battery Packs & UAV Batteries India | EVBS", "seoDescription": "Lightweight high-discharge custom battery packs for agricultural drones, survey UAVs, delivery drones and defence aerial platforms.", "keywords": "drone battery pack India, UAV battery pack, agricultural drone battery, high discharge lithium battery" }, { "id": 4, "key": "industryRobotics", "icon": "🤖", "title": "Robotics Battery Packs", "color": "cyan", "clients": "Robotics startups, cobot builders, R&D labs and automation teams", "desc": "Custom lithium battery packs for service robots, cobots, inspection robots, educational robots and embedded robotic systems.", "useCases": [ "Service robots", "Cobots", "Inspection robots", "Educational robots", "Embedded robotic systems" ], "specs": [ "Peak motor current support", "Compact packaging", "CAN / UART / Bluetooth BMS options", "Standby drain planning", "Fast-swap and safe shutdown support" ], "path": "/industries/robotics-battery-packs", "seoTitle": "Robotics Battery Packs Bengaluru | EVBS", "seoDescription": "Custom lithium battery packs for service robots, cobots, inspection robots, educational robots and embedded robotic systems.", "keywords": "robotics battery pack, robot battery pack India, lithium battery for robots, custom robot battery Bengaluru" }, { "id": 5, "key": "industryAgvAmr", "icon": "🚚", "title": "AGV & AMR Battery Packs", "color": "blue", "clients": "Warehouse automation, logistics, factory mobility and AMR teams", "desc": "High-cycle lithium battery packs for AGV, AMR, warehouse automation, logistics robots and factory mobility platforms.", "useCases": [ "AGV platforms", "AMR robots", "Warehouse automation", "Factory transport carts", "Dock-charged mobility systems" ], "specs": [ "High-cycle LFP packs", "Opportunity charging support", "Hot-swap or dock charging review", "Fleet traceability", "Robust connectors and service access" ], "path": "/industries/agv-amr-battery-packs", "seoTitle": "AGV & AMR Battery Packs India | EVBS", "seoDescription": "High-cycle lithium battery packs for AGV, AMR, warehouse automation, logistics robots and factory mobility platforms.", "keywords": "AGV battery pack, AMR battery pack India, warehouse robot battery, lithium battery for automation" }, { "id": 6, "key": "industryMedical", "icon": "⚕️", "title": "Medical Device Battery Packs", "color": "cyan", "clients": "Medical device OEMs, healthcare hardware teams and product developers", "desc": "Reliable lithium battery packs for portable ventilators, patient monitors, infusion pumps, defibrillators and mobile medical devices.", "useCases": [ "Portable ventilators", "Patient monitors", "Infusion pumps", "Defibrillators", "Mobile medical devices" ], "specs": [ "Stable backup runtime", "Conservative BMS protection", "Low self-discharge planning", "Traceability and documentation", "Safe enclosure and charger guidance" ], "path": "/industries/medical-device-battery-packs", "seoTitle": "Medical Device Battery Packs India | EVBS", "seoDescription": "Reliable lithium battery packs for portable ventilators, patient monitors, infusion pumps, defibrillators and mobile medical devices.", "keywords": "medical device battery pack India, ventilator battery pack, lithium battery for medical devices, portable medical battery" }, { "id": 7, "key": "industryIndustrial", "icon": "⚙️", "title": "Industrial Lithium Battery Packs", "color": "blue", "clients": "Industrial OEMs, field equipment makers, UPS and tool manufacturers", "desc": "Rugged lithium battery packs for power tools, field instruments, industrial UPS, mining, construction and portable equipment.", "useCases": [ "Power tools", "Field instruments", "Industrial UPS", "Construction equipment", "Portable industrial systems" ], "specs": [ "Rugged duty-cycle design", "Dust and vibration-aware packaging", "High peak-load support", "Wide temperature planning", "Field-serviceable layout" ], "path": "/industries/industrial-lithium-battery-packs", "seoTitle": "Industrial Lithium Battery Packs Bengaluru | EVBS", "seoDescription": "Rugged lithium battery packs for power tools, field instruments, industrial UPS, mining, construction and portable equipment.", "keywords": "industrial lithium battery pack, power tool battery pack India, industrial UPS lithium battery, rugged battery pack" }, { "id": 8, "key": "industryMarineDefence", "icon": "🛡️", "title": "Marine & Defence Battery Packs", "color": "cyan", "clients": "Marine, defence, ROV, communications and rugged equipment teams", "desc": "Salt-spray resistant and rugged lithium battery systems for electric boats, ROVs, defence UAVs and communication platforms.", "useCases": [ "Electric boats", "ROVs", "Defence UAVs", "Rugged communication systems", "Portable mission equipment" ], "specs": [ "Humidity and salt-spray aware design", "Shock and vibration planning", "Conservative current limits", "Clear fault reporting", "Transport and safety documentation" ], "path": "/industries/marine-defence-battery-packs", "seoTitle": "Marine & Defence Battery Packs India | EVBS", "seoDescription": "Salt-spray resistant and rugged lithium battery systems for electric boats, ROVs, defence UAVs and communication platforms.", "keywords": "marine battery pack India, defence battery pack, ROV battery, rugged lithium battery, electric boat battery" }, { "id": 9, "key": "industry3dPrinting", "icon": "🧩", "title": "3D Printing Design & Production", "color": "blue", "clients": "Startups, OEM R&D teams, makers and battery prototype teams", "desc": "3D printed battery enclosure prototypes, cell holders, jigs, fixtures and low-volume production parts for lithium battery projects.", "useCases": [ "Battery enclosure prototypes", "Cell holders and spacers", "Connector and BMS mounts", "Jigs, fixtures and test adapters", "Low-volume production parts" ], "specs": [ "CAD to print workflow", "FDM / resin prototype options", "Heat-resistant material selection", "DFM for battery assemblies", "Fast iteration in Bengaluru" ], "path": "/industries/3d-printing-design-production", "seoTitle": "3D Printing Design & Production for Battery Projects | EVBS", "seoDescription": "3D printed battery enclosure prototypes, cell holders, jigs, fixtures and low-volume production parts for lithium battery projects.", "keywords": "3D printing battery enclosure, battery cell holder design, 3D printed battery prototype, EV battery enclosure design Bengaluru" } ], "portfolio": [ { "id": 1, "cat": "EV", "industry": "Electric Vehicles", "client": "Bengaluru EV Startup", "title": "48V 50Ah LFP Pack for Electric Cargo Three-Wheeler", "challenge": "Client needed a drop-in replacement for lead-acid at same price point, with double the range.", "solution": "Engineered a prismatic LFP pack with active thermal management and CAN BMS. Achieved 2.4kWh in original battery tray dimensions.", "results": [ "Range: 80km vs 40km (lead-acid)", "Cycle life: 3,000+ vs 300 (LA)", "Weight: 8.2kg vs 14kg", "Delivered in 3 weeks" ], "tags": [ "LFP", "48V", "IP67", "BMS" ] }, { "id": 2, "cat": "BESS", "industry": "Solar Storage", "client": "Solar EPC, Tamil Nadu", "title": "100kWh LFP BESS for C&I Solar Project", "challenge": "Commercial facility needed 100kWh storage to manage peak demand and avoid grid import during peak tariff hours.", "solution": "Stacked 5× BESS-5120 units with central BMS, Modbus integration to existing inverter, and remote monitoring dashboard.", "results": [ "Peak demand cut by 65%", "₹8.2L annual savings on electricity", "ROI in 4.5 years", "Zero downtime in 12 months" ], "tags": [ "LFP", "51.2V", "Modbus", "Scalable" ] }, { "id": 3, "cat": "UAV", "industry": "Agri-Drone", "client": "AgriTech Company, Hyderabad", "title": "12S 22Ah NMC Pack for 10-Litre Agricultural Spray Drone", "challenge": "Customer needed 30+ minutes flight time with 10L payload, existing off-shelf packs limited to 18 minutes.", "solution": "Custom high-energy NMC cells with weight-optimised casing, smart BMS with flight-time remaining display to ground controller.", "results": [ "Flight time: 34 min vs 18 min", "Weight reduced by 340g", "Spray efficiency +45%", "10,000 acres covered in Season 1" ], "tags": [ "NMC", "44.4V", "Lightweight", "Smart BMS" ] }, { "id": 4, "cat": "Medical", "industry": "Medical Devices", "client": "Medical Device OEM, Pune", "title": "24V 10Ah IEC-Certified Pack for Portable Ventilator", "challenge": "Ventilator OEM needed IEC 62133 certified pack to pass CDSCO approval. Existing vendor could not provide certification.", "solution": "Designed dual-BMS redundant pack with UL94 V-0 enclosure, IEC 62133 testing, and CDSCO documentation support.", "results": [ "IEC 62133 certified", "CDSCO approval obtained", "5-year supply agreement signed", "Zero field failures in 18 months" ], "tags": [ "LFP", "IEC 62133", "Dual BMS", "Medical" ] }, { "id": 5, "cat": "Robotics", "industry": "Warehouse Robotics", "client": "Logistics Startup, Bengaluru", "title": "48V 30Ah LFP Pack for Autonomous Warehouse Sorting Robot", "challenge": "Robot needed 8-hour shift operation with opportunity charging during 15-minute breaks — no robot downtime allowed.", "solution": "Fast-charge enabled LFP pack with CAN interface to robot controller. 1C continuous charge, hot-swap mechanism designed.", "results": [ "8+ hours operation achieved", "15-min charge adds 2.5h runtime", "Zero downtime in pilot", "Scaled to 40 units in 6 months" ], "tags": [ "LFP", "CAN", "Fast Charge", "Hot-Swap" ] }, { "id": 6, "cat": "Industrial", "industry": "Power Tools", "client": "Tool OEM, NCR", "title": "36V 6Ah NMC Modular Pack for Industrial Cordless Tool Line", "challenge": "OEM building a new cordless tool line needed a battery platform compatible across 8 different tool SKUs.", "solution": "Universal 36V platform with sliding rail mechanism, NFC-based cell authentication and 12-month warranty BMS.", "results": [ "8 tool SKUs on single battery", "NFC authentication prevents counterfeit cells", "₹2.4Cr saved vs imported cells", "Launched on schedule" ], "tags": [ "NMC", "36V", "Universal Platform", "NFC" ] } ], "blog": [ { "id": 1, "cat": "Technical", "title": "LFP vs NMC: Choosing the Right Cell Chemistry for Your EV Pack", "date": "Apr 18, 2025", "author": "Priya Nair", "readTime": "8 min", "featured": true, "excerpt": "A deep dive into the trade-offs between Lithium Iron Phosphate and Nickel Manganese Cobalt cells — energy density, cycle life, thermal safety, and cost per kWh compared.", "tags": [ "LFP", "NMC", "Cell Chemistry", "EV" ], "content": "When our clients ask us \"LFP or NMC?\", the honest answer is: it depends. Both are excellent chemistries — but they excel in different scenarios.\n\nLFP wins when: Safety is paramount, cycle life matters, and energy density is not a critical constraint. Think e-buses, BESS systems, AGVs.\n\nNMC wins when: Every gram matters and you need maximum energy in minimum volume. Think UAVs, compact 2W EVs, handheld power tools.\n\nThe key numbers: LFP delivers ~150 Wh/kg at 3,000+ cycles. NMC delivers ~220 Wh/kg at 1,500 cycles. For a 2 kWh pack, that's a 3 kg difference — significant in a drone, negligible in a bus." }, { "id": 2, "cat": "Industry", "title": "AIS-156 Decoded: What Indian EV OEMs Need to Know in 2025", "date": "Apr 10, 2025", "author": "Divya Menon", "readTime": "6 min", "featured": true, "excerpt": "AIS-156 Phase II mandates have tightened. Here's what changed, what tests are now mandatory, and how to prepare your battery pack for compliance without a complete redesign.", "tags": [ "AIS-156", "Compliance", "EV OEM", "India" ], "content": "AIS-156 Phase II came into effect in April 2024, and its impacts on battery pack design are significant. The new mandates include stricter thermal runaway propagation tests, mandatory BMS over-temperature cutoffs, and enhanced short-circuit protection requirements.\n\nKey changes for battery pack engineers: The thermal runaway propagation test now requires that no external flame, no explosion, and no rupture occurs within 5 minutes of a triggered cell event." }, { "id": 3, "cat": "Guide", "title": "Battery Pack Design Checklist: 12 Things Engineers Miss", "date": "Mar 28, 2025", "author": "Rajesh Kumar", "readTime": "10 min", "featured": false, "excerpt": "A practical checklist from our engineering team — covering the most common oversights in battery pack design projects, from cell grouping errors to BMS communication pitfalls.", "tags": [ "Design", "Engineering", "BMS", "Best Practices" ], "content": "After reviewing hundreds of battery pack designs, we've compiled the 12 most common engineering oversights that cause field failures, certification rejections, and customer returns." }, { "id": 4, "cat": "Industry", "title": "How Indian BESS Startups Are Disrupting Commercial Energy Storage", "date": "Mar 15, 2025", "author": "Sneha Patil", "readTime": "5 min", "featured": false, "excerpt": "India's BESS market is growing at 45% CAGR. We look at the key players, use cases, and why domestic manufacturing is now the most competitive path forward.", "tags": [ "BESS", "India", "Market", "Solar" ], "content": "The Indian BESS market crossed ₹4,200 crore in FY2025, driven primarily by commercial and industrial (C&I) solar-plus-storage projects." }, { "id": 5, "cat": "Technical", "title": "BMS Communication Protocols: CAN vs RS485 vs Modbus — When to Use What", "date": "Feb 28, 2025", "author": "Arun Sharma", "readTime": "7 min", "featured": false, "excerpt": "Your battery pack's BMS needs to talk to the outside world. Choosing the right communication protocol can make integration seamless or a nightmare. Here's our breakdown.", "tags": [ "BMS", "CAN", "Modbus", "Protocol" ], "content": "Communication protocol selection is one of the most overlooked decisions in battery system design — until integration day, when it becomes everyone's biggest headache." }, { "id": 6, "cat": "DIY", "title": "Building a 48V 20Ah LFP E-Bike Battery: A DIY Guide", "date": "Feb 10, 2025", "author": "Karthik Reddy", "readTime": "15 min", "featured": false, "excerpt": "Step-by-step guide to building a safe, reliable 48V LFP e-bike battery using 32700 cells, a spot welder, and an appropriate BMS. Safety first — always.", "tags": [ "DIY", "E-Bike", "LFP", "Tutorial" ], "content": "This guide is for experienced electronics enthusiasts. Building lithium battery packs involves real electrical hazards — please read the safety section before proceeding." } ], "team": [ { "id": 1, "name": "Rajesh Kumar", "role": "Founder & CEO", "bg": "Electrochemistry · IISc Bengaluru · 15 yrs" }, { "id": 2, "name": "Priya Nair", "role": "Head of Engineering", "bg": "Power Electronics · NIT Calicut · 12 yrs" }, { "id": 3, "name": "Arun Sharma", "role": "BMS Lead", "bg": "Embedded Firmware · BITS Pilani · 10 yrs" } ], "milestones": [ { "id": 1, "year": "2016", "event": "Started as a DIY project while building an electric bicycle. Designed and assembled our first custom lithium battery pack." }, { "id": 2, "year": "2017", "event": "Local EV enthusiasts and riders began requesting similar battery solutions. Started building custom packs for electric cycles and small EVs." }, { "id": 3, "year": "2018", "event": "EV Battery Solutions was founded in Indiranagar, Bengaluru, focused on custom-built lithium battery packs for electric mobility applications." }, { "id": 4, "year": "2019", "event": "Delivered our first major industrial project — custom battery packs for Automated Guided Vehicles (AGVs)." }, { "id": 5, "year": "2020", "event": "Successfully developed battery systems for electric car applications, entering higher-voltage and higher-capacity battery solutions." }, { "id": 6, "year": "2022", "event": "Expanded into UAVs, drones, medical devices, and specialized industrial equipment requiring custom energy solutions." }, { "id": 7, "year": "2023", "event": "Strengthened in-house battery design, testing, and manufacturing capabilities to support increasingly complex projects." }, { "id": 8, "year": "2025", "event": "Serving customers across India and expanding globally with custom-designed battery solutions engineered from scratch for every application." } ], "faqs": [ { "id": 1, "page": "support", "q": "What is the warranty on your battery packs?", "a": "All manufactured packs carry a 12-month warranty covering manufacturing defects. Extended 24-month warranty is available as an add-on. DIY kits carry a 6-month warranty on cells and components." }, { "id": 2, "page": "support", "q": "Can I order a single unit or prototype?", "a": "Yes — we cater to B2C and DIY customers with single-unit orders. For standard catalog products, order directly. For custom packs, minimum order is 1 unit with NRE charges. Contact us for pricing." }, { "id": 3, "page": "support", "q": "How long does a custom pack project take?", "a": "A typical custom project from inquiry to delivered prototype takes 4–8 weeks: 1–2 weeks design, 2–4 weeks build & test, 1–2 weeks shipping and documentation. Timeline depends on complexity and component lead times." }, { "id": 4, "page": "support", "q": "Do you ship outside India?", "a": "Yes. We ship worldwide via DHL, FedEx and India Post. UN 38.3 transport certification is included. International orders require advance payment. Export documentation and customs support provided." }, { "id": 5, "page": "support", "q": "What certifications do your packs hold?", "a": "Pack-level testing and documentation can be aligned to IEC 62133, UN 38.3, AIS-156 for EV applications and BIS IS 16046 where applicable. Specific validation requirements depend on the product, chemistry and end-use." }, { "id": 6, "page": "support", "q": "Can you replace cells in my existing pack?", "a": "Yes — we offer cell replacement and capacity restoration services for packs manufactured by us or third parties. Send us your pack model and we'll assess. Turnaround is typically 5–10 business days." }, { "id": 7, "page": "support", "q": "Do you offer OEM / white-label supply?", "a": "Yes. We offer OEM supply with your branding, custom enclosures and documentation. MOQ for OEM supply is typically 50 units. NDAs and supply agreements are standard." }, { "id": 8, "page": "support", "q": "How do I track my order?", "a": "Once your order ships, you'll receive an email with tracking details. For large B2B orders, a dedicated relationship manager provides regular updates. WhatsApp support is also available 9AM–6PM IST." }, { "id": 9, "page": "serviceCustomPacks", "q": "Can you design a pack from only voltage and runtime?", "a": "Yes. We can convert voltage, load, runtime, size and operating environment into a practical pack specification." }, { "id": 10, "page": "serviceCustomPacks", "q": "Do you support both LFP and NMC?", "a": "Yes. LFP, NMC, LTO and LiPo are selected based on safety, cycle life, discharge current, weight and budget." }, { "id": 11, "page": "serviceBms", "q": "When do I need a smart BMS?", "a": "Use a smart BMS when the pack needs telemetry, CAN/RS485 communication, fleet diagnostics, warranty logs or regulatory traceability." }, { "id": 12, "page": "serviceBms", "q": "Can you diagnose BMS faults?", "a": "Yes. We inspect BMS logs, wiring, cell-group voltage, sensors and charger interaction before recommending replacement." }, { "id": 13, "page": "serviceCharging", "q": "Can I use a different charger?", "a": "Only if voltage, chemistry, current limit, connector and polarity match the pack. Wrong chargers can damage cells and BMS hardware." }, { "id": 14, "page": "serviceCharging", "q": "Do you provide charger recommendations?", "a": "Yes. We specify charger voltage, current, connector, cut-off profile and usage guidance for each pack." }, { "id": 15, "page": "serviceManufacturing", "q": "Can you build pilot batches?", "a": "Yes. We support prototype, pilot and low-to-mid volume production with repeatable QA checkpoints." }, { "id": 16, "page": "serviceManufacturing", "q": "Do you provide traceability?", "a": "Production packs can include serialised labels, batch records and test summaries." }, { "id": 17, "page": "serviceServicing", "q": "Can every battery be repaired?", "a": "No. Packs with severe water damage, unsafe cell condition or locked electronics may need replacement. We diagnose before quoting." }, { "id": 18, "page": "serviceServicing", "q": "Do you repair third-party packs?", "a": "Yes, if the pack construction is serviceable and safe to open at the workshop." }, { "id": 19, "page": "servicePrototyping", "q": "How long does a prototype take?", "a": "Most battery prototypes take 2 to 4 weeks after requirements, cell availability and enclosure constraints are finalised." }, { "id": 20, "page": "servicePrototyping", "q": "Can the prototype become production-ready?", "a": "Yes. We use prototype testing to identify improvements before a pilot or series manufacturing batch." }, { "id": 21, "page": "service3dPrinting", "q": "Is 3D printing suitable for production?", "a": "It is best for prototypes, fixtures and selected low-volume parts. Larger volumes may need molded or machined alternatives." }, { "id": 22, "page": "service3dPrinting", "q": "Can you help without a 3D model?", "a": "Yes. We can discuss basic design support for simple brackets, holders, covers and enclosure mockups." }, { "id": 23, "page": "serviceTesting", "q": "Do you issue final certification?", "a": "Final certification is issued by authorised test labs. We help prepare the pack, documentation and pre-compliance review." }, { "id": 24, "page": "serviceTesting", "q": "Which standards do you support?", "a": "We support preparation around IEC 62133, BIS IS 16046, UN 38.3, AIS-156 and related safety documentation." } ], "documents": [ { "id": 17, "cat": "Getting Started", "title": "Battery Requirement Sheet", "size": "PDF · 2 pages", "badge": "Checklist", "url": "/downloads/battery-requirement-sheet.pdf" }, { "id": 1, "cat": "Getting Started", "title": "Unboxing & First Charge Guide", "size": "PDF · 2.1MB", "badge": "Popular" }, { "id": 2, "cat": "Getting Started", "title": "Safety Instructions — All Packs", "size": "PDF · 890KB", "badge": "" }, { "id": 3, "cat": "Getting Started", "title": "BMS Indicator LED Reference", "size": "PDF · 340KB", "badge": "" }, { "id": 4, "cat": "Integration & Wiring", "title": "BMS Communication Protocol Guide (CAN/RS485)", "size": "PDF · 3.4MB", "badge": "Technical" }, { "id": 5, "cat": "Integration & Wiring", "title": "Connector & Pinout Reference", "size": "PDF · 1.2MB", "badge": "" }, { "id": 6, "cat": "Integration & Wiring", "title": "Charging System Integration Manual", "size": "PDF · 2.8MB", "badge": "" }, { "id": 7, "cat": "Product Datasheets", "title": "EVBS-4850 LFP Datasheet", "size": "PDF · 1.1MB", "badge": "" }, { "id": 8, "cat": "Product Datasheets", "title": "EVBS-7260 NMC Datasheet", "size": "PDF · 1.3MB", "badge": "" }, { "id": 9, "cat": "Product Datasheets", "title": "BESS-4820 Datasheet", "size": "PDF · 1.8MB", "badge": "" }, { "id": 10, "cat": "Product Datasheets", "title": "UAV-6S-12 Datasheet", "size": "PDF · 780KB", "badge": "" }, { "id": 11, "cat": "BMS Firmware", "title": "EVBS-Cloud BMS Firmware v2.4.1", "size": "ZIP · 4.2MB", "badge": "Latest" }, { "id": 12, "cat": "BMS Firmware", "title": "EVBS-Smart BMS Firmware v1.9.0", "size": "ZIP · 2.1MB", "badge": "" }, { "id": 13, "cat": "BMS Firmware", "title": "Mobile App (Android APK) v1.6.2", "size": "APK · 18MB", "badge": "" }, { "id": 14, "cat": "Compliance Documents", "title": "IEC 62133 Test Report", "size": "PDF · 5.6MB", "badge": "" }, { "id": 15, "cat": "Compliance Documents", "title": "UN 38.3 Transport Safety Report", "size": "PDF · 3.2MB", "badge": "" }, { "id": 16, "cat": "Compliance Documents", "title": "Battery Pack QA Checklist", "size": "PDF · 440KB", "badge": "" } ], "inquiries": [ { "id": 1001, "type": "Contact", "name": "Mitanshu Mowade", "company": "", "email": "mitanshumowade@gmail.com", "phone": "9689663875", "subject": "Sales / Product Inquiry", "message": "I am writing from Avisa Automotive, an EV startup developing a 3 wheeler utility vehicle, looking for battery solutions with the following requirements:\n\nCompartment dimensions : 540*400*120mm\n\n72V LFP Battery Pack, max possible capacity in the above mentioned space\n\nCould you please share any relevant product details along with the pricing regarding the same. We look forward to hearing from you\n\nBest Regards\nAvisa Automotive", "date": "2026-06-05T12:16:48+00:00", "status": "new" } ], "__updatedAt": "2026-06-05T05:54:20.546Z", "__localOnly": false }