Custom Battery Packs for Light EV and E-Bike OEM Manufacturers
PackForge Energy manufactures custom 36V–72V lithium battery packs for e-bikes, e-scooters, mobility scooters, low-speed utility vehicles and specialty mobility platforms.
From cell selection and smart BMS configuration to pack assembly, connector layout, testing and export documentation, your project is handled through our in-house engineering and production workflow.
36V / 48V / 52V / 60V / 72V battery pack configurations
Li-ion NMC and LiFePO4 chemistry options
Smart BMS, connector and harness customization
UN38.3 / MSDS / SDS / Class 9 DG shipping support
Safety, Compliance & Destination-Market Readiness for Light EV Battery Packs
PackForge reviews BMS protection, current load, thermal risk, connector layout, documentation and export requirements before sample production.
BMS Protection
Over-current, over-voltage, under-voltage, short-circuit, temperature protection and cell balancing are reviewed before pack assembly.
Current & Thermal Load
Continuous current, peak acceleration current, hill-climb load and charging heat are evaluated to avoid undersized cells, cables or BMS.
Water, Vibration & Connector Risk
Mobility battery packs are exposed to movement, moisture and repeated plug-in cycles. Pack structure, insulation, cable routing and port position need to be reviewed early.
Export Packaging & Documentation
Battery documentation and dangerous goods shipping requirements are planned according to selected cells, pack structure and destination market.
| DESTINATION MARKET | DOCUMENTATION / COMPLIANCE DIRECTION WE TYPICALLY REVIEW |
|---|---|
| United States | UL 2271 pathway review, UL 2849 e-bike system discussion, UN38.3, MSDS / SDS, Class 9 DG packaging |
| European Union | EN 50604 review, UN38.3, MSDS / SDS, EU Battery Regulation labeling and removability considerations |
| United Kingdom | UN38.3, MSDS / SDS, UKCA pathway discussion, transport documentation |
| Canada | UN38.3, MSDS / SDS, transport documentation, project-specific safety review |
| Australia / New Zealand | AS/NZS pathway review, UN38.3, MSDS / SDS, lithium battery transport documentation |
| Japan | PSE pathway discussion, UN38.3, MSDS / SDS, battery labeling and import documentation review |
Mobility Applications and Battery Pack Architecture Options
Different mobility platforms require different pack structures. We review application type, mounting position, removability, charging method, connector layout and service access before sample production.
| APPLICATION | REMOVABLE PACK | BUILT-IN PACK | SWAPPABLE PACK | MODULAR SYSTEM |
|---|---|---|---|---|
| E-bike / Cargo bike | Typical | Possible | Project discussion | — |
| E-scooter / Light moped | Possible | Typical | Possible | — |
| Mobility scooter | Typical | Possible | — | — |
| Low-speed utility vehicle | — | Typical | — | Possible |
| Golf cart / Service cart | — | Possible | — | Typical |
| Specialty mobility platform | Project discussion | Possible | Project discussion | Possible |
Removable Battery Packs
For e-bikes, cargo bikes, delivery bikes and selected mobility scooters where users remove the battery for charging, replacement or service. Key review points include handle structure, lock position, charging port, discharge connector, enclosure strength and user handling safety.
Built-In Battery Packs
For e-scooters, electric mopeds, low-speed vehicles and compact mobility equipment where the battery is installed inside the frame, base or chassis. Key review points include space constraints, cable routing, heat dissipation, mounting method, vibration exposure and service access.
Swappable Battery Packs
For fleet, rental or shared mobility projects where frequent battery replacement may be required. Key review points include pack size, connector cycle life, charging dock direction, communication requirements and safe user handling.
Responsibility boundary: PackForge manufactures swappable battery packs to OEM specifications; swap station infrastructure and network operation are handled by the customer or their integration partner.
Modular Battery Systems
For low-speed vehicles, carts and specialty platforms where capacity may be scaled by module. Key review points include parallel design, BMS coordination, fuse strategy, enclosure structure and maintenance process.
Cell Selection & Pack Configuration
We configure 18650, 21700 or prismatic cell-based packs according to voltage, capacity, discharge current, energy density, cycle life, lead time and cost target.
- Li-ion NMC for compact and energy-dense packs
- LiFePO4 for cycle life and safety-focused applications
- Cell consistency and batch review before assembly
- Series-parallel structure based on load profile
Smart BMS Configuration
We configure BMS protection and communication requirements based on motor controller, charger, current load and safety requirements.
- Over-current and short-circuit protection
- Temperature monitoring
- Cell balancing
- CAN / RS485 / UART / Bluetooth options
- Charge and discharge parameter review
- CANopen and light EV CAN matrix discussion when required
Mechanical Structure & Harness Layout
We design pack structure, connector direction and internal wiring layout around real equipment space and installation requirements.
- Custom enclosure direction
- Charge / discharge port layout
- Cable gauge and harness planning
- Vibration and insulation consideration
- Mounting and service access review
Testing & Export Documentation
We perform electrical checks and prepare lithium battery export documents based on selected cells, pack structure and shipping method.
- Capacity and voltage checks
- BMS protection verification
- Charging / discharging review
- UN38.3 / MSDS / SDS support
- Class 9 DG shipping preparation
Looking for industrial AGV or equipment batteries?
See our Industrial Equipment Battery Systems.Typical Mobility Battery Project Profiles
The examples below show typical mobility battery project profiles we are set up to review and manufacture for OEM/ODM customers.
Cargo E-Bike Battery Program
PROJECT TYPE
OEM cargo e-bike battery program
TARGET REGION
Western Europe
TYPICAL CONFIGURATION
48V mobility battery pack, 21700 cells, smart BMS with communication option
APPLICATION FOCUS
commercial delivery bike
COMPLIANCE DIRECTION
UN38.3 + EN 50604 documentation discussion
SUITABLE STAGE
sample review and pilot batch planning
Electric Scooter Battery Pack
PROJECT TYPE
E-scooter battery pack development
TARGET REGION
North America
TYPICAL CONFIGURATION
60V / 72V lithium battery pack, high-current BMS, reinforced connector layout
APPLICATION FOCUS
light electric scooter platform
COMPLIANCE DIRECTION
UL 2271 pathway review + UN38.3 + MSDS / SDS
SUITABLE STAGE
prototype specification review and small-batch planning
Low-Speed Utility Vehicle Battery
PROJECT TYPE
Low-speed utility vehicle battery system
TARGET REGION
Australia / New Zealand
TYPICAL CONFIGURATION
48V / 72V LiFePO4 battery pack, prismatic cells, charger compatibility review
APPLICATION FOCUS
campus vehicle, service cart or utility vehicle
COMPLIANCE DIRECTION
UN38.3 + MSDS / SDS + transport documentation
SUITABLE STAGE
sample-to-batch discussion
Want to discuss a similar mobility battery project?
Send Your Project RequirementsFrom Mobility Battery Sample to Batch Production
A controlled sample-to-batch workflow helps reduce specification drift between prototype approval and mass production.
Project Requirement Review
Typical timing: 1–3 working days after receiving complete project information.
We review application type, motor power, voltage, capacity, current, battery space, connector, charger, target market and annual volume.
Battery Architecture Direction
Typical timing: 2–5 working days depending on technical complexity.
We define pack chemistry, cell format, BMS rating, connector layout, charging method, enclosure direction and documentation path.
Sample Quotation & Drawing Confirmation
Typical timing: 2–5 working days after architecture direction is confirmed.
We provide a quotation based on selected cells, BMS, structure, test items, documentation and packaging requirements.
In-House Sample Assembly
Typical timing: 15–25 working days depending on cell availability, BMS configuration and enclosure requirements.
Samples are assembled in our facility, including cell grouping, BMS integration, wiring, insulation and pack structure fitting.
Testing & Customer Validation
Typical timing: 3–7 working days for internal checks before shipment; customer-side validation depends on the project.
We complete electrical checks and BMS protection verification before delivery. The customer validates fit, runtime, output, connector layout and vehicle-side compatibility.
Batch Production & Export Delivery
Typical timing: 30–45 working days after sample approval, depending on quantity, material lead time and documentation requirements.
After sample approval, batch production follows the confirmed specification. QC, packaging and export documentation are completed before shipment.
Mobility & Light EV Battery FAQ
PackForge Energy is a battery pack manufacturer with in-house engineering, assembly, testing and export documentation support. Cell selection, BMS configuration, pack assembly, wiring and QC are handled through our own production workflow.
We mainly support OEM/ODM mobility battery pack projects, not one-piece retail replacement battery orders. If you have voltage, capacity, connector, size and quantity requirements, we can review whether the project fits our production scope.
Most mobility projects we review are within 36V, 48V, 52V, 60V and 72V. Other low-voltage configurations can be discussed depending on application, quantity and technical requirements.
MOQ depends on cell model, BMS configuration, enclosure requirements and documentation scope. For custom mobility battery packs, sample orders and pilot batches can be discussed before mass production.
For most mobility battery projects, we can discuss pilot orders or initial small batches after sample approval. Pilot quantity, configuration and pricing depend on cell availability, BMS, enclosure and documentation scope.
Sample lead time is typically 15–25 working days depending on cell availability, BMS configuration, connector layout, enclosure requirements and documentation needs.
Custom battery pack samples are usually chargeable because they require cell matching, BMS configuration, wiring, assembly and testing. Sample cost can be reviewed based on the final specification and project scope.
Warranty terms are confirmed per project based on application, expected duty cycle, target market and quantity. For most mobility OEM/ODM projects, warranty covers manufacturing defects under defined operating conditions; specific coverage scope and duration are written into the project agreement before batch production.
Yes. We can configure BMS protection, current rating, temperature protection, balancing and optional communication such as CAN, RS485, UART or Bluetooth.
Yes. We review charge port, discharge port, cable gauge, connector position, harness length and waterproofing direction based on the equipment structure.
Yes, for selected OEM/ODM projects. We review pack structure, locking direction, connector cycle life, user handling safety, charging dock direction and communication requirements. PackForge manufactures swappable battery packs to OEM specifications; swap station infrastructure and network operation are handled by the customer or their integration partner.
We support certification pathway review and documentation preparation based on the project requirements. Each project's certification pathway is reviewed individually based on target market, application and customer requirements. Final certification is completed with accredited third-party laboratories according to the confirmed battery design and testing scope.
Yes. We support lithium battery export documentation including UN38.3, MSDS / SDS and Class 9 dangerous goods shipping requirements based on selected cells, pack structure and shipping method.