At ENVO, product development starts with in-house engineering. For our upcoming UPT platform, one of the most critical components we designed internally is the battery pack, which is responsible for powering performance, reliability, and safety across the entire vehicle.
To accelerate early validation, we collaborated with the BCIT Center for Applied Research and Innovation to produce the first physical prototype of our design.
In-House Design at ENVO
The UPT battery pack was fully designed by ENVO's engineering team. Every aspect of the pack, from enclosure geometry to internal layout, was developed to meet the demands of the new platform.
Optimized cell layout balances energy density, thermal behaviour, and packaging within the UPT chassis.
Built to withstand real-world conditions: vibration, shock, and impact loads typical of off-road and utility use.
Designed to integrate cleanly with the UPT system architecture, including mounting, wiring, and BMS interfaces.
Engineered with future production and scalability in mind, not just a one-off prototype.
Bringing the First Version to Life
Once the design reached its initial milestone, the next step was to physically validate it. For this phase, BCIT's Applied Research and Innovation team supported us by producing a 3D-printed version of the first design iteration.
This prototype let us check several things that are difficult to evaluate in CAD alone:
Verifying the pack sits correctly within the UPT chassis and clears surrounding components.
Reviewing how the pack is built up, how it is serviced, and how the enclosure opens for inspection.
Validating mounting points and the structural layout of the enclosure under realistic conditions.
Identifying refinements that feed directly into the next CAD iteration.
Why the First Prototype Matters
Even a well-engineered design benefits from physical validation. A first 3D-printed version is not the production part, but it does several things that pure CAD work cannot.
The first prototype catches issues that are hard to see on a screen, builds confidence in the design before committing to tooling, and shortens the path between idea and production-ready hardware. Each iteration is faster and more focused than the last.
Moving Forward
With the initial prototype completed, ENVO continues refining the UPT battery pack through iterative improvements based on testing and feedback, electrical and thermal validation, and preparation for production-ready versions.
This is how every ENVO product is developed: designed in-house, validated early, and refined through real engineering work before it reaches the road or the trail.
Engineered in Canada
From the UPT platform to our e-bikes and trikes, ENVO products are designed, tested, and supported by the team that builds them.
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