We/I wrote a lot about possible new battery packs for the Avinox system, cca 700wh and a 936Wh pack. I mentioned in my posts that these are the most likely packs based on the newest available cells on the market. I also mentioned(briefly) that due to the fact the newest cells came on the market sometime in nov/dec 2025 it is possible the new packs won't be ready till spring 2026 due to lack of time to go trough all the steps to certify a new battery pack. There are also some new regulations stepping into play this and next year so that may have an effect also.
I asked AI to throw together a summary of steps to bring a new ebike battery pack on the market. The summary example is based on the EU market, different markets also have different regulations, so additional or different testing could be needed for other world markets.
Let's say DJI/Amflow is done with steps 1 & 2, then there a still eight steps to go...
Based on the summary given timeline the best case scenario would be the end of 2026, worst case spring 2027. I think someone already mentioned next season for new Avinox packs.
AI Summary:
1. Concept, design & engineering
Start with:
• Battery chemistry (typically lithium-ion)
• Voltage, capacity (Wh), form factor
• Battery Management System (BMS) for safety (overcharge, temp, short circuit)
At this stage you also design for:
• Thermal stability (fire risk is a major concern)
• Durability (charge cycles, vibration)
• Integration with the e-bike system
2. Prototype & internal testing
Before any certification:
• Build prototypes
• Run internal tests:
• Charge/discharge cycles
• Overheating / thermal runaway
• Mechanical stress (drops, vibration)
• Water/dust protection (IP ratings)
This reduces the risk of failing formal certification later.
3. Safety standards testing (mandatory)
You must pass internationally recognized battery tests:
Core battery standards:
• UN 38.3 → transport safety (required for shipping lithium batteries) (Alibaba)
• IEC 62133 → cell-level safety standard (Alibaba)
These ensure the battery won’t explode, leak, or catch fire under normal use and transport.
4. E-bike system compliance (EU-specific)
If the battery is used in an e-bike sold in Europe:
• Must comply with
EN 15194 (e-bike standard)
• Covers electrical safety, EMC, mechanical safety (ebike battery manufacturer)
• Ensures compatibility with:
• Max 48V systems
• 250W motor limits
• 25 km/h cutoff

Important: Even if you only sell the battery, it must be compliant
within the full system.
5. CE marking (legal market entry)
To sell in the EU,
CE marking is mandatory:
• Confirms compliance with:
• Safety
• Health
• Environmental protection laws
• Without CE → cannot legally sell or import (Gdestl)
This involves:
• Risk assessment
• Technical documentation
• Declaration of conformity
6. EU Battery Regulation compliance (new & stricter)
Under the
EU Battery Regulation (2023/1542):
You must address the
entire lifecycle:
• Sustainable sourcing
• Carbon footprint reporting
• Recycling targets
• Labeling requirements (ZIV – Die Fahrradindustrie)
Upcoming requirements:
• QR code + labeling (from ~2026)
• Digital “battery passport” (from ~2027) (Xbenbike)
7. Certification testing by third parties
You typically send samples to labs (e.g. TÜV, SGS):
They perform:
• Electrical safety tests
• Mechanical abuse tests
• Environmental tests (heat, moisture, shock) (ebike battery manufacturer)
If passed → you receive certificates needed for CE marking and market trust.
8. Manufacturing & quality control setup
Before scaling production:
• Implement quality systems (e.g. ISO 9001)
• Ensure traceability:
• Serial numbers
• Batch tracking
• Lock component specs (certification applies to exact design)
9. Transport & logistics compliance
Lithium batteries are classified as
dangerous goods:
• Must follow strict shipping rules
• Special packaging + labeling required
• Often limited to ground/sea transport (Xbenbike)
10. Market launch & post-market obligations
After launch:
• Provide manuals and safety instructions
• Warranty & recall capability
• Ongoing compliance monitoring
Regulators can:
• Pull products
• Issue fines
• Require recalls (especially for fire risk)
Quick summary (simple flow)
• Design & engineer battery
• Prototype + internal testing
• Pass UN 38.3 + IEC 62133
• Meet EN 15194 (e-bike system)
• Obtain CE marking
• Comply with EU Battery Regulation
• Third-party certification
• Set up manufacturing & QA
• Arrange compliant shipping
• Launch + monitor product
Reality check
The hardest parts are usually:
• Passing safety tests (thermal runaway failures are common)
• Navigating regulations (they’re getting stricter every year)
• Documentation and traceability
Typical end-to-end timeline: 9 to 18 months
1. Concept & engineering — 1–3 months
• Define specs (voltage, capacity, form factor)
• Select cells + design BMS
• Early safety design (thermal, enclosure)

Faster if using off-the-shelf components

Slower if developing new chemistry or custom electronics
2. Prototyping — 2–4 months
• Build first working units
• Iterate design (usually multiple revisions)
Includes:
• Mechanical housing tweaks
• BMS tuning
• Early safety fixes

Most teams underestimate this phase
3. Internal testing & validation — 2–3 months
• Charge/discharge cycles
• Thermal stress testing
• Drop / vibration / water resistance
Goal: avoid failing formal certification later
4. Certification testing — 3–6 months
This is often the
biggest bottleneck
Includes:
• UN 38.3 (transport)
• IEC 62133 (battery safety)
• EN 15194 (e-bike system compliance)
• CE documentation

If you fail tests, add
+2–6 months for redesign and retesting
5. Manufacturing setup — 1–3 months (overlaps with certification)
• Finalize suppliers
• Tooling for enclosure
• Quality control processes
6. EU Battery Regulation compliance — parallel (adds ~1–2 months)
• Labeling
• Documentation
• Recycling / traceability setup
This is increasingly important after the new regulation rollout.
7. Logistics & launch prep — 1–2 months
• Packaging for dangerous goods shipping
• Distribution setup
• Manuals, warranty system
Fast-track vs slow-track
Fastest possible: ~6–9 months
Only if:
• Using proven battery cells
• Reusing existing BMS design
• Experienced team
• No certification failures
More realistic(startups): 12–18 months
Because of:
• Iterations after failed tests
• Supplier delays
• Documentation gaps
• Certification queues (labs can be booked months out)
Where most delays happen
1. Certification failures
• Thermal runaway issues
• BMS not cutting off properly
• Mechanical damage during testing
2. Documentation (CE compliance)
• Missing technical file
• Poor risk analysis
3. Supply chain
• Battery cells (often long lead times)
• Custom enclosures