An electric bicycle manufacturer was developing a new range of commuter and utility e-bikes for urban transportation, delivery services, and rental fleets.
The company needed a compact and reliable battery pack that could deliver sufficient riding range while fitting into different bicycle frames. It also required multiple voltage and capacity options to support several e-bike models within the same product family.
After evaluating standard battery products, the manufacturer decided to work with Surlon Power on a custom NCM lithium battery pack solution.
The customer faced several design and performance requirements:
Multiple voltage options for different e-bike models
Higher energy capacity within a limited frame space
Stable discharge performance during acceleration and hill climbing
Compatibility with existing controllers and chargers
Reliable protection for daily commercial operation
Flexible housing and connector configurations
Consistent battery quality for volume production
For e-bike applications, battery design affects much more than riding range. Battery size, weight, cell arrangement, thermal performance, BMS configuration, and mounting design all influence the final riding experience.
The customer therefore needed a battery manufacturer capable of supporting both cell selection and complete battery pack integration.
Surlon Power developed a customized NCM lithium battery solution based on the customer’s electrical and mechanical requirements.
NCM lithium-ion cells were selected to provide a practical balance between energy density, pack size, weight, and output performance. Surlon Power’s product range includes NCM e-bike battery configurations such as 36V 10.5Ah, 36V 14Ah, 36V 17.5Ah, and 36V 21Ah models. The company also lists 48V configurations for selected e-bike applications. View Surlon Power battery pack products
The battery pack design process included:
Voltage and capacity configuration
Cell selection and matching
Pack structure design
BMS integration
Connector and wiring configuration
Housing and mounting compatibility
Charge and discharge protection
Production consistency testing
Surlon Power provides support from individual battery cells to complete OEM battery pack assembly. Its custom lithium battery service is designed to meet specific voltage, capacity, space, and application requirements. Learn more about Surlon Power custom lithium battery packs
Cell consistency is essential for the reliability of a multi-cell battery pack. Differences in capacity, internal resistance, and voltage can affect pack performance and service life.
To address this challenge, Surlon Power applies cell inspection and matching procedures. The company’s public product information highlights capacity testing, voltage verification, internal resistance measurement, and cell consistency screening.
For the e-bike project, matched NCM cells were arranged according to the required voltage and capacity. This helped create a more stable battery system and supported consistent performance across different production batches.
The custom NCM battery pack was equipped with a battery management system designed to monitor and protect the battery during operation.
The BMS can support key protection functions such as:
Overcharge protection
Over-discharge protection
Overcurrent protection
Short-circuit protection
Temperature monitoring
Cell balancing
State-of-charge management
These safety functions are important for e-bikes used in demanding environments, including daily commuting, delivery services, and rental fleets.
Surlon Power also provides BMS and accessory solutions for customized battery systems, helping manufacturers coordinate the battery pack with the controller, charger, and vehicle electronics. Explore Surlon Power BMS solutions
One of the main advantages of a custom NCM battery pack is design flexibility.
Instead of using one standard battery for every product, the manufacturer could select different capacities for different e-bike models. Lower-capacity packs could support lightweight commuter bicycles, while higher-capacity configurations could be used for delivery or long-range applications.
Surlon Power also offers Hailong-style e-bike battery pack configurations. Its published specifications include 48V options with 20Ah, 25Ah, and 30Ah capacities, a 13S4P cell arrangement, and an integrated 30A BMS. These configurations are intended to help manufacturers evaluate voltage, capacity, frame fit, charger compatibility, and controller requirements together. View the Hailong battery pack fit guide
The customized NCM lithium battery pack helped the e-bike manufacturer address several product development goals:
Improved energy density within a compact package
Flexible voltage and capacity options
Better compatibility with different frame designs
Stable power delivery during normal operation
Integrated battery protection
Easier adaptation for OEM and ODM production
More consistent battery quality across production batches
The modular approach also allowed the customer to develop several e-bike models using related battery technologies instead of creating a completely different battery system for each model.
For e-bike manufacturers, the battery is one of the most important components affecting product performance, customer satisfaction, and operating cost.
A custom battery pack can help manufacturers optimize:
Riding range
Vehicle weight
Charging time
Frame integration
Maintenance requirements
Production efficiency
Product differentiation
By working with Surlon Power from cell selection through pack assembly, the customer gained access to a more integrated battery development process. This reduced the need to coordinate multiple suppliers for cells, BMS components, wiring, housing, and final assembly.
This case demonstrates how custom NCM lithium battery packs can support the development of modern electric bicycles.
By combining matched NCM cells, customized voltage and capacity configurations, intelligent BMS protection, and flexible housing options, Surlon Power helps e-bike manufacturers develop battery systems that are better aligned with their vehicle designs and operating requirements.
Whether the application requires a compact commuter battery, a long-range delivery e-bike pack, or a Hailong-style battery for an existing frame, Surlon Power provides customized lithium battery solutions for OEM and ODM projects.
For technical specifications, custom pack design, and project consultation, visit SurlonPower.com.
