PCB boards adapted for electric motorcycles (e-motorcycles) are high-performance components designed to handle higher power (1kW–15kW) and more demanding operating conditions than e-bike PCBs, supporting e-motorcycles’ faster speeds, longer ranges, and heavier loads. These PCBs integrate powertrain control, battery management, and safety systems, requiring robust design to withstand vibration, temperature fluctuations, and high power dissipation.

Core functional blocks include: a high-power motor controller (with IGBTs to drive the e-motor, supporting speeds up to 10,000 RPM), an advanced BMS (monitoring 72V–144V battery packs with cell balancing to extend life), and a vehicle control unit (VCU) interface for integrating brakes, lights, and dashboard displays. PCBs use high-Tg FR-4 (Tg ≥170°C) or polyimide material for thermal stability, and feature thick copper (3–5 oz) for power traces and thermal vias to manage heat from IGBTs.

Design considerations include vibration resistance (using reinforced solder joints and shock-absorbing mounting) and EMC compliance (to avoid interference with navigation or communication systems). Many e-motorcycle PCBs support fast charging (via DC charging modules) and regenerative braking to improve range. For example, PCB boards for Zero Motorcycles’ SR/F model integrate a SiC-based controller to reduce energy loss and enable 140-mile range. These PCBs are essential for e-motorcycles’ performance, safety, and reliability, making them a key component for manufacturers targeting the premium or commuter e-motorcycle market.