PCB circuit boards for electric bicycles (e-bikes) are compact, cost-effective components that control the e-bike’s motor assist, battery charging, and user interface—designed for low-power (250W–750W) operation and compatibility with e-bike’s small form factor. These PCBs integrate essential functions while prioritizing lightweight design and energy efficiency, suitable for urban commuting and leisure e-bikes.

Key modules on these PCBs include: a motor controller (with low-power MOSFETs to regulate motor speed based on pedal input or throttle signals), a battery protection circuit (preventing overcharging/discharging of 36V/48V lithium-ion batteries), and a user interface interface (connecting to LED displays for speed, battery level, and assist mode). PCBs use standard FR-4 material (Tg ≥150°C) with 1–2 oz copper layers, and feature a 2–4 layer design to minimize size (typically 50mm×100mm or smaller).

Design optimizations include low-power consumption (to extend battery range) and waterproofing (IP65 rating) for outdoor use. Many e-bike PCBs support Bluetooth connectivity to pair with smartphones, enabling features like ride data tracking or remote lock/unlock. For example, PCB boards for Bosch Active Line e-bike systems integrate pedal torque sensors to provide seamless motor assist, enhancing riding comfort. These PCBs are critical for e-bike performance, ensuring reliable motor operation, long battery life, and user-friendly functionality. For e-bike manufacturers, cost-effective, durable PCBs help balance performance and affordability in the consumer market.