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ESP32-Based IoT PCBA — From Ready Stock to Rapid Mass Production.
New Energy PCBA Manufacturing for Energy Storage Monitoring Circuit Board 1
New Energy PCBA Manufacturing for Energy Storage Monitoring Circuit Board 1

New Energy PCBA Manufacturing for Energy Storage Monitoring Circuit Board

Industry: New Energy / Energy Storage
Scope of Service: DFM Analysis | Heavy Copper PCB Manufacturing | SMT Assembly | ICT / FCT | Aging Test
Technical Highlights: 6-layer heavy copper PCB, high-current power loop, thermal optimization, overvoltage/overcurrent protection, batch traceability
  
Final Outcomes & Measurable Value
1.Thermal Performance: The optimized BMS PCBA lowered peak temperature and passed long-cycle charge-discharge reliability testing.
2.Compliance: Complete traceability documentation ready for EU certification audit.
3.Business Value: NPI completed smoothly, supporting the customer’s small-batch pre-production validation for home energy storage products.
5.0
design customization

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    Client Background & Initial Challenges

    The customer is a Germany-based startup developing residential lithium energy storage systems. Their original BMS design had thermal concentration risks on the power MOSFET area, and their previous assembly partner could not meet full batch component traceability requirements.
    Key Challenges
    Technical: High-current power circuit with strict thermal dissipation requirements, and support for continuous charge-discharge cycle testing.


    Manufacturing: Heavy copper PCB and large power devices with heat dissipation pads.


    Compliance: Full component batch traceability required for EU safety certification audit.
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    MTI End-to-End Solution
    DFM & Thermal Review: Analysis of power loop layout, copper area expansion and thermal via optimization to reduce local overheating.
    Heavy Copper PCB & SMT: Fabrication of a 6-layer heavy copper board with a special reflow profile for large power components to prevent delamination and cold solder.
    Multi-stage Testing: ICT for open/short circuit detection, FCT for protection function verification, and continuous aging burn-in test to validate thermal performance.
    Supply Chain & Traceability: Sourcing of power semiconductors and passive components via authorized channels, recording batch code, lot number and COC documents.
    Post-assembly Inspection: Visual plus AOI inspection of power device solder quality.
    Final Outcomes & Measurable Value
    Thermal Performance: The optimized BMS PCBA lowered peak temperature and passed long-cycle charge-discharge reliability testing.


    Compliance: Complete traceability documentation ready for EU certification audit.


    Business Value: NPI completed smoothly, supporting the customer’s small-batch pre-production validation for home energy storage products.
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    Visual Proof & Testimonial
    Client Quote: “Thermal risk was our biggest concern. MTI’s engineering suggestions greatly improved our BMS board stability for energy storage application.”

    — 03 · MTI Engineering Approach

    Redesigning the hardware architecture

    Our engineering team focused on:

    New Energy PCBA Manufacturing for Energy Storage Monitoring Circuit Board 6
    Nordic BLE module integration
    Our in-house designers and engineers have produced countless great designs for customers from different
    New Energy PCBA Manufacturing for Energy Storage Monitoring Circuit Board 7
    Low-power circuit optimization
    Choose us, and we promise to do everything needed to ensure a successful and satisfactory working
    New Energy PCBA Manufacturing for Energy Storage Monitoring Circuit Board 8
    Sensor interface design
    We boast offering unmatched, cost-effective manufacture that caters to industry.
    New Energy PCBA Manufacturing for Energy Storage Monitoring Circuit Board 9
    PCB layout improvement
    ustomers choose us because we provide leading technology, deliver unmatched products and services.
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    Component selection according to production requirements
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    Contact person: Vincent
    Tel: +86 186 1703 7035
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