A power circuit may pass initial tests but fail in a sealed enclosure under peak load, low temperature, or real use. That’s why we integrate batteries, converters, chargers, and BMS into the full product architecture, accounting for heat, EMC, safety, certification, and production from the start.
Power electronics may pass bench tests yet fail inside a sealed enclosure due to heat buildup, switching noise, grounding issues, or layout constraints. So we address these early – before they cause certification or redesign problems.
Battery-powered products need more than basic protection – aging, temperature, and loads can distort SoC readings and affect safety. Hence, we design BMS with charge estimation, balancing, abuse protection, and temperature behavior from the start.
Medical, wearable, and industrial products often require IEC 62133, IEC 60601-1, EMC directives, or other standards. Сertification constraints influence topology, isolation, PCB layout, and protection logic from the beginning.
Work that highlights the incredible technologies, solutions, and products EnCata developed
EnCata developed an 8K VR headset for sports training which featured ultra-high resolution, a wide field of view, and compact dimensions. It allowed real-time interaction between players in different places. The prototype was ready for pilot production in just 8 months.
display resolution
field of view
We helped an electric mobility startup turn a raw prototype into a smart, IoT-connected skateboard for city commuting. The device is a reliable, eco-friendly, convenient, and intelligent type of urban transport with the possibility of integration into urban infrastructure.
filed as a result of our R&D efforts
final weight (2–3× lighter than typical alternatives)
EnCata delivered UAV engineering services, designing and manufacturing an autonomous drone docking station with charging, climate control, and positioning systems. The product supports surveillance, delivery, and inspections in Arctic to desert conditions.
max take-off weight
max host drone diameter
EnCata helped a startup develop a smart soil irrigation system from concept to MVP. The system includes custom electronics, BLE, LoRaWAN, and solar-powered modules for real-time soil monitoring and control. Built and tested in just 8 months.
range of operation
remotely through the mobile network and directly via Wi-Fi modules
EnCata developed a minimum viable product – a robot for factory and warehouse automation. It can carry loads of up to 200 kg, operate autonomously for 3 hours without recharging, and features a 120×80×40 cm platform.
load capacity
operating time under load
EnCata developed a smart kitchen appliance for a European company entering the smart home market. We delivered feasibility studies, electronics, firmware, and a working prototype for a device that brews coffee, tea, and prepares baby formula.
to cool water from 100 °C to 38 °C
filed during development
EnCata engineered an IoT rodent detection system with movement sensors and NB-IoT data transfer. The system detects rodent activity and sends data to the cloud. The project spanned from electronics design and 3D modeling to prototype development and a 10-unit pilot batch in 6 months.
standby current of the first prototype
time to manufacture 10 prototypes
The following scope of work is based on where battery and power systems most often create risk: early architecture choices, thermal and EMC behavior inside the enclosure, BMS accuracy under real conditions, and production constraints that appear before pilot builds.
Each stage is designed to catch these issues before layout, BOM, or certification decisions become expensive to change.
We define the power architecture before hardware development begins: input voltage range, battery chemistry, charging strategy, power rails, operating modes, and certification constraints.
This gives you a clear electrical architecture before critical power, safety, and compliance issues surface in testing.
We develop DC/DC converters, charging systems, protection logic, fuel gauge integration, and communication interfaces based on real operating conditions.
For battery systems, we cover balancing, SoC estimation, overcurrent protection, thermal protection, and hardware-firmware interaction.
We define switching loops, grounding, current paths, and thermal dissipation at layout, before prototype issues appear.
Prototypes are validated under load for charging behaviour, thermal performance, electrical stability, and protection timing.
We refine the system for manufacturing, certification, and pilot production through DFM updates, production-ready PCB revisions, CE/TÜV/IEC-related validation planning, and manufacturing documentation.
We also qualify alternate components before the BOM is locked, reducing the risk of production delays caused by single-source gate drivers, protection ICs, or other critical parts.
Our team is eager to discuss how we can assist you and answer any questions you may have. Don't hesitate to reach out!
We deliver CE- and IEC-ready power systems at reasonable budgets.
The difference is not engineering depth. It is lower project overhead.
Our experience with power electronics and BMS development helps identify thermal, EMC, protection, and architecture issues early, reducing redesign cycles before certification.
We work with startups and product teams worldwide and deliver hardware internationally.
We develop power electronics and BMS with the CE, TÜV certification requirements in mind.
Power systems must operate reliably under electrical, thermal, and production constraints.
To achieve this, we focus on:
Fault protection should not rely on hardware or firmware alone. We cover overvoltage, undervoltage, overcurrent, overheating, and short-circuit scenarios across the full system.
We select components with lifecycle, availability, and production scaling in mind to reduce redesign risks during later stages.
Bench spec at 25°C doesn't predict behavior inside a sealed enclosure. We run thermal models before layout is frozen using real enclosure geometry, not open-bench assumptions.
Buck converter noise can couple into CAN or I²C lines through shared ground paths, with failures appearing only under load. We define grounding strategy and switching loops from the first revision.
Depends on complexity, certification scope, and validation cycles
Electrical architecture, battery configuration, operating modes, certification targets, and production limitations.
Power stage, battery monitoring, protection logic, and communication interfaces.
System validated under real electrical and thermal conditions, including charging, protection, and load scenarios.
System developed for manufacturing, certification, and pilot production.
Deep domain understanding increases the success rate of your product.
At first glance, a battery-powered device may seem simple: connect a battery, add a charging port, and the system should work.
In practice, even a compact power system includes many interconnected components that affect the entire product design.
Heat from power components affects PCB layout, component spacing, enclosure ventilation, and sometimes even device size.
Protection against overcurrent, overheating, and short circuits adds monitoring ICs, MOSFETs, sensing circuits, and firmware logic.
Current paths, filtering, isolation distances, and connector placement directly influence PCB layout and enclosure geometry.
This path shows how a battery or power electronics system moves from architecture validation to a production-ready design.
Is the selected power architecture viable?
Does the system operate as intended?
Does the system remain stable under real conditions?
Is the system ready for certification and pilot manufacturing?
We share our approach to product development, engineering decisions, and real project experience. No marketing noise — just practical insights and structured thinking.
Power electronics and BMS development is structured around the failure modes that cause late-stage redesigns – from constraints to production-ready design.
Ready to define the architecture? Fill out the contact form.
