What I Did
I designed and built an e-bike battery pack using 18650 cells, with a focus on clean packaging, service access, and reliable integration into the bike.
Personal
E Bike Battery Pack
A custom battery pack project focused on packaging lithium-ion cells into a practical, serviceable system for an electric bike, with attention to electrical protection, mechanical restraint, and thermal awareness.
Why I Did It
E-bike batteries are expensive, so why not build one? The project gave me a practical way to learn pack design while making something useful.
How I Did It
I balanced cell layout, current paths, BMS wiring, insulation, and enclosure geometry so the pack could be assembled, inspected, and protected during use.
Cell Sorting
I organized the measured 18650 cells into balanced groups before assembly, so each parallel set started from a more consistent capacity and voltage profile.
Spot Welding
I spot welded nickel strip onto the cell groups to build the main current paths while keeping heat away from the cells and protecting the pack with insulation layers.
BMS Wiring
I soldered the BMS wiring and balance leads into place, routing the harness cleanly so the protection circuitry could be inspected without disturbing the full pack.
Battery Pack Optimizer GUI
I also built a Python GUI to organize measured cells into balanced pack groups, check voltage spread, visualize the layout, and export the results for assembly. More information can be found in the report below.
