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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Please fill out the form below to request a quote or to request more information about us. please be as detailed as possible in your message, and we will get back to you as soon as possible with a response. we're ready to start working on your new project, contact us now to get started.
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.
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.
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
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Nordic BLE module integration
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Low-power circuit optimization
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Sensor interface design
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PCB layout improvement
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Component selection according to production requirements
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