Traction battery being aligned with an electric vehicle chassis during an engineering integration review

EV TRACTION BATTERY ENGINEERING

Lithium Battery Systems for Electric Vehicles

Custom LFP and NMC battery systems for electric cars, commercial vehicles, EV conversions, utility vehicles, tuk-tuks and specialty electric vehicles — from low-voltage platforms to high-voltage traction systems.

  • 48V–700V+ Systems
  • LFP & NMC
  • Custom Pack Engineering
  • BMS & CAN Integration
  • Prototype to Production
Explore EV Battery Systems Discuss Your EV Project

VEHICLE-FIRST ENGINEERING

EV Battery Platforms Built Around Your Vehicle

Battery selection starts with vehicle voltage, motor and controller, installation space, peak current, range target, charging architecture and communication requirements. Bonnen can begin with an existing platform and adapt the final system around the vehicle instead of forcing every project into one fixed enclosure.

48V–700V+Voltage Platforms
LFP & NMCCell Chemistry
Custom BMS & CANVehicle Integration
Prototype → ProductionProject Support

EXISTING EV PLATFORMS

Explore Our Electric Vehicle Battery Systems

Browse our existing EV battery platforms below. Voltage, capacity, enclosure, BMS, communication and interfaces can be adapted to the final vehicle requirements.

Don’t see an exact match? Send us your motor/controller specifications and available battery space.

Share your current specifications →

APPLICATION FIT

EV Battery Systems for Different Vehicle Platforms

Vehicle layout, duty cycle, voltage, current demand and production programme all influence the final battery architecture.

Engineers reviewing a classic car during a professional electric conversion project
01

Passenger & Classic Car Conversion

Custom traction battery systems for EV conversions and low-volume vehicle programmes.

Electric delivery van being loaded at a commercial logistics depot
02

Light Commercial EVs

Battery platforms for vans, delivery vehicles, utility vehicles and municipal fleets.

Low-speed electric utility vehicle supporting maintenance work on an industrial campus
03

Low-Speed & Utility Vehicles

Solutions for LSVs, patrol vehicles, sightseeing vehicles and utility EVs.

Electric cargo tuk-tuk being loaded for commercial three-wheel delivery work
04

Tuk-Tuks & Three-Wheelers

72V and 96V platforms for passenger, cargo and commercial three-wheel vehicles.

Engineers evaluating a low-profile electric airport ground-support tow tractor
05

Specialty Electric Vehicles

Custom battery architectures for unconventional vehicle layouts and OEM projects.

VOLTAGE ARCHITECTURE

EV Battery Systems Across Multiple Voltage Platforms

These ranges show typical project directions. Final system voltage must be confirmed against the motor, controller, charger, current demand and complete vehicle architecture.

48V–72VTypical for utility vehicles, LSVs and three-wheelers.Explore 48V systems →
72V–144VTypical for EV conversions and specialty vehicles.Explore 72V systems →Explore 96V systems →
200V–400VTypical for passenger and light commercial EVs.
400V–700V+Typical for high-power and high-voltage vehicle platforms.

Typical, not fixed: vehicle type and voltage range do not have a one-to-one relationship. Every project requires system-level confirmation.

PROJECT PATH

Start With an Existing Platform — or Build Around Your Vehicle

Existing Battery Platform

A practical starting point when the vehicle can work within an established electrical and mechanical envelope.

  • Compatible voltage range
  • Flexible installation envelope
  • Current demand within an existing platform
  • Shorter development path
Review an Existing Platform

Custom EV Battery

Use a vehicle-specific architecture when packaging, interfaces or electrical demand fall outside an existing platform.

  • Fixed or irregular installation space
  • Special enclosure geometry or mounting
  • Specific CAN protocol and vehicle interfaces
  • High continuous or peak current
  • Custom HV distribution or thermal management
Discuss a Custom EV Battery

PROJECT BRIEF

What We Need to Size Your EV Battery

Don’t have all of this information yet? That’s fine. Send the specifications you currently have, and our engineering team can help identify the remaining battery requirements.

Send Available Project Data
Vehicle Type
Motor Power
System Voltage
Range or Runtime
Battery Space / CAD / STEP
Communication & Vehicle Interfaces
Illustrative exploded view of an EV traction battery enclosure, modules and high-voltage components

COMPLETE SYSTEM ARCHITECTURE

More Than Cells and an Enclosure

A vehicle battery is a complete electrical and mechanical system. Bonnen engineers the cell configuration, BMS, HV protection, communication, enclosure, thermal management and vehicle interfaces as one integrated battery architecture.

Grade-A Cells / ModulesConfigured around energy and power requirements.
BMSMonitoring, protection and system control.
HV Junction BoxHigh-voltage switching and distribution.
Contactors & FuseProtection sized for the final architecture.
MSDService disconnect strategy where required.
CAN CommunicationCoordination with controller, charger and vehicle.
Thermal ManagementSelected against duty cycle and environment.
HV / LV InterfacesConnectors and harnesses matched to the vehicle.
Sealed EnclosurePackaging, mounting and service access reviewed together.

VERIFIED PROJECT DIRECTIONS

EV Engineering Examples

Three examples supplied for this page show how vehicle constraints translate into different battery architectures.

GermanyBatch Production

96V Classic Car Conversion

Initial constraint
Limited installation space and compatibility with the existing conversion drivetrain.
Engineering response
Custom 96V traction battery platform with vehicle-specific enclosure and BMS configuration.
United StatesBatch Production

332.8V Light Commercial EV

Initial constraint
Higher-energy traction system within a defined commercial vehicle chassis envelope.
Engineering response
332.8V battery architecture developed around vehicle power, current and installation requirements.
ThailandBatch Production

72V Electric Tuk-Tuk

Initial constraint
Daily commercial operation requiring reliable cycle life and practical vehicle integration.
Engineering response
72V LFP battery system optimized for three-wheel vehicle packaging and operating profile.

DEVELOPMENT PROCESS

From Vehicle Data to Production Battery

Each stage resolves electrical, mechanical and integration questions before the programme advances.

Requirements

Vehicle, motor, controller and battery space.

Battery Architecture

Voltage, capacity, cells and BMS.

Mechanical Engineering

Enclosure, mounting and interfaces.

Prototype & Validation

Electrical, communication and environmental checks.

Production

Pilot batch to planned production.

MANUFACTURING & VALIDATION

Engineered for Vehicle Integration and Production

Production planning connects pack assembly, control-system integration and defined end-of-line checks to the agreed vehicle and programme requirements.

Pack assembly
BMS & harness integration
Insulation & electrical checks
Charge / discharge testing
End-of-line inspection
Project-specific validation support
Battery pack assembly and electrical validation in a controlled industrial workcell

FAQs About Lithium Battery Systems for Electric Vehicles

Practical answers to common questions about EV battery selection, system integration, customization, BMS communication and project development.

The battery should be matched to the motor voltage, continuous and peak power, controller current, required driving range, available installation space and charging system. For custom EV projects, these parameters should be considered together rather than selecting the battery only by voltage or capacity.

Battery capacity depends mainly on the vehicle’s energy consumption and required driving range. A preliminary estimate can be made from expected Wh/km consumption × target range, while vehicle weight, speed, terrain, temperature, usable SOC range and system efficiency should also be considered.

The correct battery voltage depends on the motor, controller and overall vehicle architecture. Light EVs may use 48V, 72V or 96V systems, while passenger vehicles, commercial EVs and higher-power platforms often use 144V, 300V, 400V or higher-voltage battery systems.

LFP batteries are commonly selected for long cycle life, thermal stability and durability, while NMC batteries can provide higher energy density where battery weight and installation space are more critical. The best chemistry depends on the vehicle application and project priorities.

Yes. We can develop custom battery dimensions, enclosure layouts and mounting structures according to the available installation space. CAD drawings, STEP files or maximum length, width and height are especially useful during the battery design process.

Yes. We can design the battery around your existing motor and controller specifications, including nominal voltage, operating voltage range, continuous current, peak current and communication requirements. Providing motor and controller datasheets helps us size the battery more accurately.

The most useful information includes vehicle type, motor power, system voltage, continuous and peak current, target driving range or operating time, available battery space, charging requirements and communication protocol. Even if some information is not yet confirmed, we can help review the project step by step.

Yes. The BMS can be configured according to the battery voltage, current requirements and vehicle control strategy, and CAN communication can be developed to exchange information with the vehicle controller, charger, dashboard or other electronic systems.

It depends on battery power, charging rate, operating environment and duty cycle. Some EV battery systems can use passive or air cooling, while higher-power or more demanding applications may require liquid cooling, heating or other thermal management solutions.

Yes. Bonnen develops EV lithium battery systems across a wide voltage range, from low-voltage platforms such as 48V, 72V and 96V to high-voltage battery systems for passenger vehicles, commercial EVs and special electric vehicles.

Yes. Custom EV battery projects can normally begin with prototype development and testing before moving to pilot production and larger-volume orders. This allows the battery design, vehicle integration and communication functions to be verified before mass production.

Depending on the project, EV battery packs can undergo electrical testing, insulation checks, charge and discharge testing, BMS function verification, communication testing and final inspection before shipment. Additional validation requirements can also be discussed according to the vehicle application.

START YOUR PROJECT

Have an EV Project? Start With the Vehicle Requirements.

Send us your motor/controller specifications, target voltage, required range or battery energy, and available installation space. Our engineers can evaluate an existing platform or develop a custom EV battery system for your vehicle.

Discuss Your EV Battery Project