Custom Liquid Cooled Lithium Battery System with PDU

Custom Liquid-Cooled 21700 NMC Battery System (with PDU + customized BMS) A purpose-built pack for aerospace and high-duty platforms. We use wire-bonded 21700 NMC cells to drive very low interconnect resistance and repeatable current sharing, then pull heat through a liquid-cooling manifold so power is stable across long duty cycles. A tightly integrated PDU handles high-voltage switching, safety, and serviceability. The BMS is profiled to your mission—charge/discharge limits, derates, alerts, and balancing are tuned to your envelope, not the other way around. Architecture Cells: 21700 NMC with aluminum wire/ribbon bonds to minimize interconnect resistance and improve current sharing. Redundant paths where required. Thermal: structural liquid-cooling manifold sized to the array, designed for uniform ΔT and repeatable power. Leak-checked loops and serviceable purge/bleed. PDU: main and charge contactors, pre-charge, service disconnect, HV fusing/pyro option, current sensing, HVIL, and keyed HV connectors. Clear lockout/tagout points. BMS: cell-level voltage/temperature, balancing, contactor control, insulation monitoring integration, data logging, and a custom CAN map to the customer’s avionics or vehicle controller. What “custom BMS profile” means Mission-specific current, voltage, temperature, ramp rates, derates, and fault logic aligned to the platform’s thermal model and duty cycle. Deterministic startup/shutdown handshakes and state machine definitions. Telemetry fields, sampling rates, and on-pack logging defined for flight/ground test. Documentation deliverables (e.g., DVP&R inputs, FMEA contributions, ATPs) aligned to the customer’s quality flow. Integration notes Pack voltage/capacity scale by S/P; busbars, manifold, and fusing are sized accordingly. Enclosure and mounts engineered to program shock/vibration and environmental targets; venting/relief strategy as required. Compliance support available for UN38.3 transport and additional environmental/EMI testing per statement of work. Outcomes you can expect Tight cell-to-cell temperature spread, predictable run-to-run performance, and clearer end-of-life forecasting. Faster commissioning via connectorized PDU/BMS, defined profiles, and known-good telemetry. A serviceable design with documented procedures for ground crews. About EVolve Battery Systems EVolve is both a COTS OEM and a custom battery engineering team. On the COTS side, our Lithium Block™ modules (Energy or Power, 5P–10P) and MonoLith™ packs give programs a proven starting point with spec sheets, STEP files, and manuals—useful for fast prototyping and risk reduction. On the custom side, we design and build lithium-ion systems for R&D and prototype production: mechanical, thermal, electrical, and controls, including wire-bonded 21700 architectures, liquid cooling, integrated PDUs, and BMS development (profiles, CAN dictionaries, test tooling). We also support verification and early qualification (test plans, data packages, and transport readiness). If you need an off-the-shelf building block, we ship COTS. If you need a pack engineered to your envelope and standards, we build to spec. | Gen2 Lithium Block™ — Modular Wire-Bonded Battery Modules for Scalable Systems The Gen2 Lithium Block™ from CIE Solutions is a compact, air-cooled lithium-ion battery module engineered for modular energy systems requiring high current, high reliability, and flexible integration. Built around ultrasonically wire-bonded 18650 cells , each unit is optimized for demanding applications in robotics, autonomous systems, vehicle electrification, and defense prototyping environments. Modules are available in 5p to 10p configurations , offering nominal capacities up to 125 Wh (Energy variant) or 210A discharge (Power variant) ( Higher currents are available upon request ). Designed with an emphasis on system safety and configurability, each module includes integrated cell voltage and temperature monitoring , cell-level fusing , and low-resistance aluminum current pathways —delivering excellent thermal behavior and cycle stability in series configurations up to 500 VDC . Core Architecture Wire-bonded interconnects (99.997% aluminum, 300–500µm): reduce contact resistance, eliminate mechanical terminals, and enhance vibration tolerance Sensor-integrated PCB : monitors each cell’s voltage and temperature, protected by urethane conformal coating Thermistor array : 5 NTC sensors per module routed to an 8-pin Molex harness with resettable fuse protection Tool-less mechanical integration : via pre-threaded stainless inserts and optional CIE mounting arrays Passive cell-level fusing : protects against internal shorts with experimentally validated fuse thresholds Busbar-ready terminals : spaced at 25.5 mm centers with low-profile copper collector plates Performance Options Energy Modules: 52–125 Wh, 17.5–35 Ah Max discharge: 100A (10p config) Voltage: 2.5–4.2 V per module Ideal for endurance-focused applications Power Modules: 50–103 Wh, 14–28 Ah Max discharge: up to 210A across 6p–10p configurations; higher current ratings available upon request Voltage: 2.5–4.2 V per module Suited for propulsion, acceleration, or transient load support Cycle and thermal degradation profiles are provided for both cell chemistries, showing high retention over 400+ cycles and robust performance from -40°C to +60°C. Designed for Integration Series/parallel stackable in 1SxP configurations with CIE or third-party busbars Standard JST GH signal connectors simplify wiring to standard BMS platforms Compatible with CC-CV charging profiles up to 4.2 V/cell UL94-V0 flame-rated ABS housing with IP-aware vent clearance recommendations Designed and assembled in Boulder, Colorado, with optional system support and pack design consulting Applications Swarm robotics and ground vehicle propulsion UAV & autonomous system powertrains Portable and mobile field power systems Modular lab and university testbeds Defense and aerospace subsystem validation Electrified retrofits and low-volume EVs CIE Solutions provides short lead times, flexible MOQ, and engineering collaboration to help integrators accelerate development while avoiding the overhead of large-scale manufacturing. The Gen2 Lithium Block™ enables you to build production-grade systems at prototype speed.