To meet the extreme demands of mountain boards, we developed a range of custom Li-ion battery packs. These packs were designed to provide continuous discharge of over 100A and to withstand intense use conditions, including steep climbs and jumps.
The challenge:
Mountain boards require batteries with a high energy density and continuous discharge of over 100A. Additionally, the packs needed to be robust enough to resist vibrations and shocks while maintaining a compact and efficient design.
The solution:
To meet these requirements, we used the 3D FDM (Fused Deposition Modeling) technology to create the internal components of the battery packs. The casings were printed from ABS, a durable and flexible material. This process allowed us to create custom supports for cells and complex internal components, optimizing space and providing excellent adaptability.
The packs were designed with a capacity of over 1.2 kWh and voltages between 50V and 80V. We used 5mm carbon fiber or aluminum caps, cut with CNC, for maximum protection. Samsung 40T, Samsung 50S, and Molicel P45 cells provide continuous discharge of over 100A, which is ideal for intensive mountain board use. The packs also include an intelligent BMS with Bluetooth, enabling real-time monitoring and adjustment.
Results:
- Over 1.2 kWh capacity and voltages between 50V and 80V.
- Continuous discharge of over 100A.
- Use of 3D FDM printing for custom internal components made of ABS.
- Carbon fiber and aluminum caps for superior protection and durability.
- Excellent performance in hill climbing and supporting extreme jumps.
- Intelligent BMS with Bluetooth for easy monitoring.
This solution highlights the advantages of using 3D FDM printing to create custom, durable components for Li-ion battery packs, demonstrating our adaptability and efficiency in responding to the extreme demands of mountain boards.
