PCB Based Modular Flight Safe Battery Pack

The Federal Aviation Administration (FAA) places restrictions on passengers flying on commercial flights, and one such restriction is the prohibition of batteries with a capacity exceeding 99 watt-hours on board. For individuals like me who are passionate about electric skateboarding, this regulation presented a significant obstacle to traveling with our boards. However, where there's a will, there's a way, and I decided to get creative and find a solution.

To overcome this challenge, I ventured into the world of printed circuit board (PCB) design software. My goal was to create smaller individual battery modules using PCBs that I could later assemble into a larger battery pack, all without the need for tools or a soldering iron. The process began with designing these specialized PCBs, and you can see some of the initial designs in the images below. Each PCB was crafted to house two sets of 1s3p batteries, resulting in a total configuration of 2s3p per PCB. Additionally, balance leads for the Battery Management System (BMS) were thoughtfully routed directly into the PCB, making it user-friendly and convenient.

PCB Design:

This modular approach allowed me to bypass the FAA's battery capacity restrictions while still maintaining the performance and range of my electric skateboard. Plus, the ease of assembly made it a hassle-free process, ensuring that I could put together the larger battery pack whenever needed. The images below depict the final product, showcasing the culmination of my efforts. With these innovative PCB-designed battery modules, I not only found a practical solution to a regulatory challenge but also gained valuable experience in PCB design, making my electric skateboard travel-ready and hassle-free.

Final Product: