Not a DIY guide
Battery Build
Transparency into how we build the battery that powers 100 km of range.
This is not a DIY guide. This is how we build every battery pack — shared for transparency so you know exactly what is inside your aircraft. Battery construction requires specialized equipment and training.
Battery Specifications
Configuration4S4P (16 cells)
CellsSamsung 50E 21700
Nominal Voltage14.8V
Capacity20,000 mAh (288 Wh)
Pack Weight~1,200g
BMS4S 30A HiLetgo
ConnectorXT60 (power) + JST-XH (balance)
Construction Process
Each battery pack goes through five stages of construction and testing.
1
Cell Matching
All 16 Samsung 50E cells are tested for internal resistance and capacity. Cells are matched within 5% to ensure balanced discharge.
2
Spot Welding
Pure nickel strip is spot-welded to cell terminals. No soldering — spot welding preserves cell integrity and provides reliable connections.
3
BMS Integration
4S 30A HiLetgo BMS is wired for overcharge, over-discharge, and overcurrent protection. Balance leads connected for cell-level monitoring.
4
Safety Insulation
Fish paper between cell groups, Kapton tape on exposed terminals, heat shrink wrap on the complete pack. No exposed conductors.
5
Connector & Testing
XT60 power connector and JST-XH balance connector are soldered and heat-shrunk. Pack undergoes charge/discharge cycle verification.
Safety & Handling
- + Store at room temperature, 40–60% charge for long-term storage
- + Charge with a balance charger that supports 4S Li-ion
- + Never charge unattended or immediately after flight
- + Inspect pack for damage, swelling, or loose connections before each flight
- + Replacement packs available through Flightony support
Questions about the battery?
Our team can help with charging, storage, and replacements.
Contact Support