A high-performance battery is a complete system—not simply a collection of cells. Voltage, capacity, discharge demand, physical fit, BMS limits, interconnects and thermal behaviour must work together.
At dogeTune, every custom pack follows a defined process from engineering to final validation.
1. Engineer the pack around the bike
We begin with the bike, controller, available space and riding goal. The required series-parallel layout, cell type, current path, BMS position and cable exits are planned before assembly. This lets us balance power, range, weight and fitment without relying on a generic enclosure.
2. Grade and group the cells
Cells are checked and grouped before they enter a pack. The aim is consistent behaviour across each parallel group, because one weak or mismatched group can limit the performance of the entire battery.
3. Fixture and weld with repeatable tooling
Cells are loaded into purpose-built fixtures that hold the planned geometry and alignment. Automated spot-welding equipment then applies the programmed connection pattern with controlled positioning. Interconnect design is matched to the expected current—not selected by appearance alone.
4. Build in electrical and mechanical protection
Insulation, cell supports, current collectors and structural components are prepared for the specific design. CNC-cut parts help maintain accurate fit around complex pack shapes. The BMS, balance harness, power cables and connectors are then integrated as one electrical system.
5. Inspect and validate before handover
Before the pack is closed, we verify polarity, group progression, weld placement, balance wiring, insulation and cable routing. Machine-vision inspection supports consistency checks, while electrical testing confirms pack voltage, group readings and charge-discharge behaviour.
Built for the application, not the catalogue
dogeTune builds custom lithium-ion battery packs for high-performance e-bikes, Razor projects, Fiido upgrades and specialist applications. Tell us your bike model, controller voltage and current, available battery space and riding goal. We will help identify a suitable configuration before the build starts.
Planning a custom battery? Contact dogeTune to discuss your requirements.
Safety note: the battery, charger, controller, cables and connectors must be specified as a complete system. Vehicle modifications may also affect local road-use legality.