Custom eVTOL Battery Pack Solutions for Air Mobility

Our eVTOL battery packs are designed to meet the requirements of the OEM and flight time will vary due to many factors – such as the aircraft design, payload, and operating conditions. We work with OEMs to ensure the optimal battery pack design meets their specific requirements.

It depends on the aircraft design and how it is intended to be used. In some applications, particularly where fast turnaround times are critical, eVTOL battery packs can be designed to be replaceable or hot-swappable. A hot-swappable design allows the battery to be exchanged without fully powering down the aircraft, reducing ground time between flights.

The feasibility of a hot-swappable solution depends on several factors, including system architecture, safety requirements, power management and regulatory considerations. For other use cases, a fixed or non-hot-swappable battery may be more appropriate. We work in close collaboration with our customers to ensure battery configuration aligns with operational needs and certification requirements.

As an eVTOL battery pack manufacturer, we understand the specific quality and safety demands of the aerospace and aviation industries.  For example, we can design customised Battery Management Systems (BMS) that monitor temperature, voltage, and current in real-time to ensure the battery continues safe operation until the aircraft has landed. The battery pack is equipped with a fail-safe design, which is where the eVTOL battery pack will operate at a reduced output to enable the vehicle to return to the ground safely. Limiting the available power allows for a controlled descent, ensuring the pilot’s safety.

Off-the-shelf battery packs often cannot meet the specific performance, weight, and integration requirements of eVTOL aircraft. Custom battery packs are essential for achieving optimal energy density, flight time, and compatibility with vehicle systems.

Standard battery packs offer limited flexibility and may fall short in meeting the technical demands of eVTOL applications. Custom battery packs are designed to align precisely with the energy, weight, size, and safety requirements critical for electric vertical take-off and landing aircraft.

The design phase for an eVTOL battery pack typically takes between 1–3 months. The full project timeline takes about a year. This includes design, prototyping, regulatory compliance, testing followed by mass production. Depending on the complexity of the requirements involved, timelines may vary. Get started with your product requirement today!

As eVTOL technology is still emerging, most battery packs for these aircraft are based on lithium-ion chemistry due to their high energy density and compact size. Lithium-ion remains the preferred option for delivering the performance and range required in aviation applications, with the cylindrical 21700 cell being the most common format for eVTOL battery packs due to its optimal balance of energy density, safety, and cost-effectiveness.

Although both applications serve different purpose, when designing and manufacturing a UAV battery pack the same principles to make the UAV operational apply to the EVTOL. Both applications require a high energy density, lightweight and robust battery pack but will require different certifications, due to the human element of an eVTOL.