Research and Development of a High-Power, High-Energy Battery System (250 Wh/kg-Class) for Electric Aviation

1. Research Overview

This Research addressed one of the most critical challenges in electric aviation: achieving high energy density (Wh/kg) battery packs without compromising power output, structural reliability, and operational safety. The research focused on designing, building, and validating a lithium-ion battery pack that exceeds 250 Wh/kg at the pack level, delivers 8C (720A @ 90Ah) high discharge, and complies with aviation-grade safety standards such as UN 38.3 and vibration/drop testing.

2. Research Motivation

In the aerospace sector, battery systems face competing demands:

Conventional battery systems rarely meet all three. Our goal was to integrate these conflicting requirements into a single, flight-ready system through engineering-driven research.

3. Technical Objectives

4. My Contributions

As Principal Investigator, I led the full-stack development of the battery system:

5. Engineering Approach

5.1 Cell Selection & Configuration

5.2 Mechanical Architecture

5.3 Thermal Management

5.4 Electromagnetic Compatibility

5.5 Battery Management System

5.6 Compliance Testing

6. Validation and Testing – Extended Dataset

6.1 Cell Grading and Variation

Figure 1
Figure 1. Pre-assembly cell grading process.
Figure 2
Figure 2. Cell capacity distribution and deviation.
Figure 3
Figure 3. Thermal estimation due to cell IR variation.

6.2 Thermal Modeling and CFD

Figure 4
Figure 4. CFD study for prototype #3 operational conditions.
Figure 5
Figure 5. Transient simulation by C-rate and ambient temp.
Figure 6
Figure 6. Comparison between prototype #3 and final version.
Figure 7
Figure 7. Preliminary CFD of final battery module.
Figure 8
Figure 8. Temperature rise (cell, tab, heatsink) after 60s discharge.

6.3 Final Prototype and Assembly

Figure 9
Figure 9. Final battery module (assembled).
Figure 10
Figure 10. Pre-test inspection photo.

6.4 Electrical and Safety Testing

Figure 11
Figure 11. CCCV and DCCV test data.
Figure 12
Figure 12. Dielectric withstand test.
Figure 13
Figure 13. Insulation resistance measurement.

6.5 Performance and Qualification Results

Figure 14
Figure 14. Discharge rate (8C): 720A for 1 minute (PASS)
Figure 15
Figure 15. Energy density: Target 250 Wh/kg → Result 253.81–257.49 Wh/kg
Figure 16
Figure 16. Low temp performance: -20°C → sustained function to -43°C
Figure 17
Figure 17. Thermal runaway isolation time: 15 min delay before propagation
Figure 18
Figure 18. Charge time to 90%: ~10 minutes
Figure 19
Figure 19. Vibration test: 7–200 Hz sweep (PASS)
Figure 20
Figure 20. Altitude test: 11.6 kPa, 6 hr (PASS)
Figure 21
Figure 21. Drop test: 1000 mm (PASS)
Figure 22
Figure 22. Humidity test (PASS)
Figure 23
Figure 23. Acceleration test: 3G (PASS)
Figure 24
Figure 24. Mechanical shock test (PASS)

7. Research Outcomes

8. Applied Product

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