Customer Case Study

Light Mobility Battery Project

Custom Lithium Battery Packs for E-Bikes, E-Scooters and Electric Motorcycles

RYDBATT developed a family of custom light mobility lithium battery packs for a B2B customer serving electric pedal-assist bikes, commuter e-bikes, electric scooters, electric motorcycles and shared battery-swapping fleets. The project was designed around high-frequency daily riding, frequent charging, outdoor use and long-term fleet operation.

This case shows how RYDBATT helped the customer move from mixed, inconsistent replacement battery supply to a reliable lithium battery programme with better discharge stability, smart BMS protection, project-matched housings and full private-label customization.

The customer was a light mobility distributor and brand serving e-bike, e-scooter and electric motorcycle operators in an overseas market. Their own customers built and sold pedal-assist bikes, commuter e-bikes, electric scooters and shared battery-swapping fleets for urban transportation, last-mile delivery and rental programmes.

Before working with RYDBATT, the customer faced several problems with their existing battery supply:

• Nominal capacity did not translate into stable usable range across a full working day
• Voltage sag appeared quickly under hill-climb and high-load riding conditions
• Housing formats did not fit the compartments already in service on their models
• After-sales complaints rose during rainy seasons and peak-season heavy-use periods
• The customer needed one battery partner able to cover several platforms instead of several suppliers
• Existing suppliers could not support flexible customization for connectors, BMS thresholds, casing dimensions and private-label packaging

The customer wanted a battery programme that could support high-frequency charging and discharging, stable power output, safer operation, verifiable cycle life and better long-term performance across e-bike, e-scooter, electric motorcycle and battery-swapping applications.

RYDBATT designed a custom light mobility lithium battery programme based on the customer's vehicle system, controller current, target riding range, installation space, waterproof rating and fleet operating conditions. The same nominal voltage meant very different things across the customer's models, so each platform was engineered from the working conditions rather than from a catalogue number.

Cell Selection

RYDBATT selected grade-A high-energy-density Li-ion cells suitable for light mobility duty. High-energy-density NCM was paired with a 18650 or 21700 format for the e-bike and scooter platforms, while LiFePO4 was reserved where daily deep discharge and cost dominate over weight. Cell configuration was designed to support stable discharge, real-rated capacity and repeated daily charge-discharge cycles.

Smart BMS Design

The battery packs used a smart BMS with protection functions including overcharge protection, over-discharge protection, overcurrent protection, short-circuit protection, temperature monitoring and active cell balancing. State-of-charge accuracy was held within ±3%, and thresholds were set per platform rather than per catalogue, with continuous and peak limits matched to the controller rating and the target riding load.

For fleet operation, RS-485, CAN, UART and SMBus communication was available so the customer could read battery status into their own controller or app, improve asset management and reduce battery loss risk. Cloud monitoring was optional for rental and shared-fleet deployments.

Heavy-Duty Metal Housing

RYDBATT developed housings around the compartments already in service across the category - water-bottle, downtube, triangle and metal-case formats - so a replacement pack is normally a drop-in rather than a re-engineering project. Casing dimensions, mounting position, connector direction and IP65/IP67 requirements were all taken from the customer's own models, and tooling was only required where the enclosure geometry was genuinely new.

Connector and Charger Matching

Charging and discharging connectors were customized according to the customer's e-bike, e-scooter and electric motorcycle systems. RYDBATT also matched the charger specification with the battery voltage, BMS setting and charging current requirements, including the controller's charge cut-off voltage, so a pack cannot be over- or under-charged in daily use.

Project-Based Customization

The final battery solution supported:

• 36V / 48V / 60V / 72V / 73V voltage options
• 7.8Ah–50Ah standard range across 18650 and 21700 formats, project-based capacity design
• Smart BMS protection with active cell balancing and ±3% SOC accuracy
• RS-485 / CAN / UART / SMBus communication, optional cloud monitoring
• Water-bottle, downtube, triangle and metal-case housing customization
• Charging and discharging connector customization, charger matching
• Label, logo, barcode, user manual and packaging customization
• OEM/ODM production for distributor and brand projects, with UL, CE and CB available

Before sample approval and mass production, RYDBATT carried out a complete testing and validation process to verify battery performance, safety and batch consistency. Every pack was verified for capacity, internal resistance, discharge curve and temperature behaviour, alongside safety testing for needle penetration, crush and over-charge, environmental validation from -40°C to +85°C with performance decay held within 5%, and mechanical reliability through 2,000 vibration cycles and 100cm drop testing.

After sample testing and customer-side vehicle verification, the light mobility battery packs passed the required performance checks and were approved for mass production.

The customer received a more stable lithium battery programme covering e-bike, e-scooter, electric motorcycle and shared battery-swapping applications. Compared with the previous mixed battery supply, the new packs helped improve discharge stability, reduce after-sales complaints and support better product consistency across their whole model range.

✓Samples passed customer testing

✓Battery packs entered batch production

✓Stable delivery across e-bike, e-scooter, electric motorcycle and swapping-fleet applications

✓After-sales complaints were reduced compared with previous supply

✓Customer placed repeat orders after initial shipment

✓Product line expanded from one battery configuration to multiple voltage, capacity and housing options

✓The customer started promoting the battery for e-bike, e-scooter, electric motorcycle and battery-swapping projects

Light mobility batteries must perform under more demanding conditions than ordinary consumer batteries. Riders may charge and discharge the pack every day, ride in outdoor environments, carry heavier loads and require stable output during long working hours - and in shared fleets the pack is handled by many different users who have no idea what condition it is in.

For this type of B2B project, the key is not only battery capacity. The battery must match the vehicle system, controller current, charger, connector, casing space, waterproof requirement and fleet management needs. A 48V pack for a 250W commuter and a 48V pack for an 800W trail bike need different cell configurations, different BMS thresholds and different housings.

RYDBATT's project-based battery development helped the customer build a more reliable light mobility battery product line for high-frequency urban use, backed by the 84,000 m² Huizhou manufacturing base, in-house BMS development and documented cycle-life, safety and communications testing for every project.

The same RYDBATT platform covers five light mobility sub-scenarios. Each one carries its own cell configuration, BMS thresholds, housing format and charger profile, and each maps to a dedicated product category on the website.

The following models are drawn from the live product range mapped to the Light Mobility scene. Full catalogue coverage runs to 110 mapped products across four categories; the list below covers the platforms most often specified in first projects.

The eight capability blocks below describe the standard engineering capabilities RYDBATT applies to every light mobility project.

4.1 Cell Customization

We select the chemistry, format and configuration against the duty cycle rather than from a catalogue. High-energy-density NCM and LiFePO4 routes are both available, with cell format, capacity and discharge rate sized to the pack envelope you actually have to fit.

Light mobility application: For light mobility we typically pair high-energy-density NCM with a 18650 or 21700 format, and reserve LiFePO4 where daily deep discharge and cost dominate over weight.

4.2 Modular Structural Design

Housing is developed around the compartment you already run - footprint, terminal layout, mounting points and connector direction - so an upgrade does not require re-engineering the vehicle. Tooling is only required where the enclosure geometry is genuinely new.

Light mobility application: Housings follow the formats already in service across the category - water-bottle, downtube, triangle and metal-case - so a replacement drop-in is normally the default rather than a project.

4.3 Smart BMS System

Protection covers over-charge, over-discharge, over-current, short-circuit and temperature, with active balancing and cell-level monitoring. State-of-charge accuracy is held within ±3%, and communication is available over RS-485, CAN, UART and SMBus, with the message list defined together with your controls team.

Light mobility application: BMS thresholds are set per platform rather than per catalogue, with continuous and peak limits matched to the controller rating and the target riding load.

4.4 Full Lifecycle Management

Traceability runs from incoming cell inspection through cell sorting, module assembly, end-of-line test and shipment records, and remains available for after-sales support. Battery management firmware can be updated remotely, and cell or module replacement is possible where the format allows, reducing service cost rather than replacing the whole pack.

Light mobility application: From incoming cell inspection through cell sorting, module assembly and end-of-line test, with shipment records retained for after-sales support across a multi-year fleet life.

4.5 Authoritative Certifications

Certification scope is confirmed per project and per destination market: UN 38.3 for transport, CE for the European market, UL where the destination requires it, and RoHS for restricted substances. The manufacturing base operates under ISO 9001, ISO 14001 and ISO 45001.

Light mobility application: UL, CE and CB are the working set for this segment, with UN 38.3 for transport and RoHS for restricted substances.

4.6 Rigorous Testing

Every pack is verified for capacity, internal resistance, discharge curve and temperature behaviour before shipment, alongside safety testing for needle penetration, crush and over-charge. Environmental validation covers -40°C to +85°C with performance decay held within 5%, and mechanical reliability is checked through 2,000 vibration cycles and 100cm drop testing.

Light mobility application: Cycle life, safety and communications testing is documented per project, which is what allows a fleet buyer to compare packs on test basis rather than on headline capacity.

4.7 Smart Manufacturing Strength

The Huizhou base covers 84,000 m² of built-up area, with 45,000 m² of production floor and a 10,000 m² logistics warehouse. Automated assembly holds ±1mm placement tolerance, and the in-house charge-discharge test systems read to ±0.05% precision. Cell procurement scale and modular design reduce mass-production cost by 15-20%.

Light mobility application: The 45,000 m² production floor and ±1mm assembly tolerance matter most here, because a light-mobility pack is a high-volume, tight-tolerance part.

4.8 ODM Customization Service

Private label and ODM projects are supported end to end, covering cell selection, BMS design, enclosure and connector specification, label, warning sticker, barcode, user manual, colour box, carton mark and packaging design - suitable for distributors, brands, repair markets and fleet operators.

Light mobility application: Logo, label, packaging, manual, barcode and carton mark are all project items, which is what distributors and brands need for a private-label programme.

Every light mobility project runs through the same nine-step process, so the responsibility for each stage is clear at every point of the programme.

Providing these twelve items up front allows us to confirm pack fit, electrical compatibility and certification scope before any sample work begins.