Battery Pack (LiPo)
Power SystemsmediumHigh-discharge lithium polymer cells configured as 4Sβ6S packs (14.8β22.2V). Must deliver 100A+ burst current for aggressive flight. The heaviest single component on most drones.
What this part does
4 functions- Stores the energy for the entire flight.
- Delivers short bursts of 100A+ during aggressive throttle.
- Heaviest single component β defines total flight time and weight.
- Recharges in ~20 minutes through a balance charger.
How to make it
5 steps- 1SortMatch cells by capacity
- 2WeldSpot-weld nickel tabs
- 3Wire upXT60 + balance lead
- 4Cycle testCharge/discharge QC
- 5SleeveHeat-shrink + label
Each step happens at a real manufacturer β scroll down to see who can do it and where.
Manufacturing Processes
Materials
Key Requirements
- β’Cell matching & sorting capability
- β’Spot welding or tab welding
- β’Balance lead assembly
- β’Charge/discharge cycle testing
- β’UN38.3 certification for shipping
Bill of Materials
- 1.Li-Po cells (4S/6S configuration)
- 2.Nickel tabs or wire bonds
- 3.XT60 / XT90 connector
- 4.Balance lead (JST-XH)
- 5.Heat-shrink sleeve
- 6.Capacity/C-rate label
Matched Manufacturers
8 of 8 Β· sorted by scoreInferred from Wayback enrichment of company website
- +Offers wire harness
- βMaterial Lithium NMC not listed (may still be capable)
- +Quantity 500 within range (0ββ)
Inferred from Wayback enrichment of company website
- +Offers wire harness
- βMaterial Lithium NMC not listed (may still be capable)
- +Quantity 500 within range (0ββ)
Inferred from Wayback enrichment of company website
- +Offers wire harness
- βMaterial Lithium NMC not listed (may still be capable)
- +Quantity 500 within range (0ββ)
Inferred from Wayback enrichment of company website
- +Offers wire harness
- βMaterial Lithium NMC not listed (may still be capable)
- +Quantity 500 within range (0ββ)
Inferred from Wayback enrichment of company website
- +Offers wire harness
- βMaterial Lithium NMC not listed (may still be capable)
- +Quantity 500 within range (0ββ)
Inferred from Wayback enrichment of company website
- +Offers testing inspection
- βMaterial Lithium NMC not listed (may still be capable)
- +Quantity 500 within range (0ββ)
Inferred from Wayback enrichment of company website
- +Offers testing inspection
- βMaterial Lithium NMC not listed (may still be capable)
- +Quantity 500 within range (0ββ)
Inferred from Wayback enrichment of company website
- +Offers testing inspection
- βMaterial Lithium NMC not listed (may still be capable)
- +Quantity 500 within range (0ββ)
Supply Chain Decision Guide
Compare sourcing strategies, understand risks, and see the path to production.
The β¬2B CALB Sines gigafactory (operational 2027-2028) will make Portugal an EU battery hub. Start pack assembly now with imported cells; vertically integrate cell supply later.
Sourcing Options
Import premium cells (Molicel P42A, Samsung 50S) from authorized distributors. Assemble packs at MeterBoost Portugal β spot welding, balance leads, QC testing.
- Fast turnaround β 1-2 weeks assembly
- Custom configurations (4S/6S, any capacity, any connector)
- Cell matching for consistent performance
- EU Battery Regulation compliant from day one
- CALB Sines integration path (2027-2028) for full localization
- Cells still imported (Molicel Canada/Japan, Samsung Korea)
- Higher cost than Chinese packs at small volume
- UN38.3 certification needed (β¬3-8K per design, one-time)
Source finished packs from EU battery companies β Gens Ace Europe, ISDT EU, or specialist EU LiPo assemblers. Rebrand with your specs.
- No assembly infrastructure needed
- Pre-tested, pre-certified packs
- EU warehouse β 1-2 week delivery
- CE + UN38.3 already handled by manufacturer
- Limited to their standard configurations
- Higher per-unit cost (β¬35-60)
- Less control over cell selection and matching
- Dependent on their stock availability
When CALB's 15 GWh gigafactory in Sines opens (2027-2028), partner directly for cell supply. LFP cells manufactured in Portugal β fully local supply chain.
- Fully local supply chain β cells + assembly in Portugal
- Massive capacity (15 GWh β no supply constraints)
- LFP chemistry β safer, 3000+ cycle life
- Strongest "Made in EU" story possible
- Not available until 2027-2028
- LFP has lower energy density than LiPo (15-20% heavier packs)
- CALB may prioritize EV contracts over small drone orders
- Unproven for high-C-rate FPV drone applications
Buy finished LiPo packs from CNHL, Tattu (Gens Ace China), or GNB. Cheapest but maximum dependency.
- Cheapest per-unit cost (β¬15-30)
- Proven high-C-rate performance for FPV
- Ready to use β no assembly needed
- Dangerous Goods shipping β expensive air freight (β¬5-15/kg extra)
- EU Battery Regulation compliance burden falls on importer (YOU)
- Quality variance β cells may be B-grade without disclosure
- No customization β take what they offer
- Full China supply chain dependency
Supply Chain Risks
Required for shipping lithium batteries. Testing costs β¬3-8K per design. Takes 4-6 weeks.
From August 2025: CE marking, carbon footprint labeling (A-G grades 2026), collection/recycling obligations.
Counterfeit cells (fake Molicel, Samsung) are common. One bad cell can cause fire.
Path to Production β 6 weeks total
Choose cell (Molicel P42A or Samsung 50S). Order samples. Test C-rate, IR, capacity matching.
Design pack layout β cell configuration, tab routing, balance leads, connector placement.
Build 10 prototype packs. Spot weld tabs, assemble balance leads, heat-shrink.
Flight test with prototypes. Submit for UN38.3 testing if shipping commercially.
500-unit batch. Cell matching, assembly, QC, labeling.
Open Source Resources
Low-cost modular BMS/balancer for lithium packs β Arduino-based, KiCad PCBs
Modular STM32-based BMS with passive balancing β KiCad PCB designs
Professional open-source modular BMS platform β suitable for production scaling
Specialized 3S LiPo BMS design using bq78350R1 + bq79620 β KiCad files
Regulatory & Compliance
- βΈEU Battery Regulation 2023/1542 β CE marking, carbon footprint label
- βΈUN38.3 testing for air/sea transport
- βΈIEC 62133 safety standard
- βΈWEEE producer registration
- βΈDG shipping certification for logistics partner
Deep Intelligence
Design best practices, technology evolution forecasts, materials supply chain analysis, and prototyping partners.
