Lion PowerCustom Battery Management System Design
Cell monitoring, balancing, and protection electronics for battery packs — automotive and industrial grade.
Design considerations
What actually goes into a custom BMS design.
| Cell monitoring & balancing | Per-cell voltage and temperature monitoring, with passive or active balancing chosen based on pack size, cell count, and how much balancing current the application actually needs — not a fixed default. |
| Protection thresholds | Overvoltage, undervoltage, overcurrent, and over-temperature cutoffs set from the specific cell's datasheet limits and your use case, with independent hardware protection backing up the firmware limits rather than relying on software alone. |
| State estimation | State of charge (and state of health, where the application calls for it) estimated from voltage, current, and temperature data — coulomb counting and/or voltage-based methods, matched to the accuracy the application actually needs. |
| Automotive & industrial grade | Where the application calls for it, design follows automotive/industrial practices — component qualification, isolation between high-voltage and low-voltage domains, and robustness to the vibration and temperature range those environments involve. |
What clients say
Quoted feedback from past projects.
Samo and his team took our project of developing the world's first USB-C charging for eBikes. Their expertise quickly identified improvements in our ideas and their commitment delivered the final product before the deadline. This allowed us to beat our competition as first to market.
We were experiencing issue after issue with our motor controller modules and that's why we decided to get our own motor controller developed. Engineers at Lion Power made a really high-quality product which cut our field failure rate by 80%. Definitely recommend.
We just completed our second project with Samo and are planning a third one. We went through a few 'low budget' freelancers before we found Samo and the results were 'low quality', like expected. Samo really turned things around for us. He took over the whole electronic system development and perfectly integrated with our mechanical department. The result was a high-power battery-operated LED light that passed all certifications with ease and is successfully selling.
We hired Samo because we needed scientific grade motor controllers for our robots that we just couldn't find elsewhere. Samo proved to be a reliable and trustworthy partner as he quickly and diligently responded to many requirement changes from our side during the project. Recommend.
I had an academic paper that described the high-voltage power supply necessary for our product. I reached out to more than 20 contractors and they all declined because they just didn't see the value in studying and learning something new. Samo gladly took up the challenge, reviewed multiple other academic papers, proved as a worthy discussion partner, improved upon the idea and finally built the power supply. It is now manufactured in multiple thousand units annually. Best contractor I had.
The stock motor drives that we used in our heat pump just didn't perform well enough and the price was ridiculous. We decided to invest in the development of our own drive so that we could own the design and manufacture it at a lower cost. Samo and his team proved more than adequate and they delivered the designs and validated prototypes ahead of schedule. This cost for our motor drive was reduced by 60%. Best investment we made.
How we work
The same sequence, whether the deliverable is one board or a small production run.
Consult
Define the electrical and mechanical constraints — load, environment, volume, timeline.
Design
Topology, component selection, schematic and layout — reviewed against the real requirements.
Prototype
Bring-up, bench testing, and firmware to get a working unit in your hands fast.
Validate
Thermal, load, and reliability testing against the conditions the product will actually face.
Deliver
Production-ready documentation, firmware, and hand-off — or ongoing support, as needed.
Selected work
A few recent battery management system builds, framed by the problem they solved.
Ultra-Compact Battery Pack for a Deep-Sea Light
A two-level cell configuration packed more capacity into a deep-sea light's tightly constrained battery volume — extending operating time 50% with no increase in product size.
Complete Electronics Platform for a Deep-Sea Exploration Light
Four boards, one team — charger, BMS, LED driver, and battery pack, developed end-to-end so the client's electronics could run fully outsourced.
Integrated Charger and BMS for a High-End Electric Road Bike
A compact, integrated charger and BMS let the frame get shaped around aerodynamics and rider comfort — not around bulky electronics.
Want to bring a project to life?
Send over what you're building and what it needs to do. We'll get back to you at the email you provide.