Mobile EV chargers are being regarded as a major solution to grid restrictions, and can provide emergency charging in response to temporary disasters, as well as offer more flexible charging services in both urban and rural areas. For businesses or individuals that can manage it, a mobile energy storage solution integrated into an EV fast charging system is now a practical and cost-effective direction.
In this article, we explore two primary methods to build your own mobile charging station:
A modular DIY approach, using battery modules and DC fast charging components.
A semi-integrated approach, using a pre-built battery cabinet combined with a DC fast charger.
Each approach offers unique benefits depending on your team’s technical expertise, budget, and deployment needs.
Charge Ninja Mobile EV Charging Solutions
Approach 1: Assemble from Battery Modules + DC Charging Components
This system is designed for teams that want maximum flexibility and control over their costs. You’ll need to source and assemble all the components yourself, hands-on, with control over every part of the build, at the cost of specialists in electronics, cooling, and integration.
Core Components:
Battery Modules (LiFePO₄):
Typically rated at 3.2V and 100–300Ah, connected in series-parallel to build total capacities of 100–250kWh. Proper BMS integration is essential.DC Charging Module (DCDC):
A 60–160kW module capable of delivering fast DC output (usually 200–1000V) to EVs via CCS2 or GB/T standards.Battery Management System (BMS):
Monitors voltage, temperature, current, and cell balancing. Prevents overcharging, deep discharge, and thermal events.Energy Management System (EMS):
Controls overall power flow, SOC management, time-of-use charging, and cloud/OCPP interfaces for remote operation.Cooling System:
Air or liquid-based, depending on charge/discharge rates and energy density. Liquid cooling is recommended for systems >150kWh.Safety Infrastructure:
Includes fuse protection, DC isolators, fire suppression units, and insulation monitoring devices.Enclosure and Mounting:
All components must be housed within a weather-resistant trailer or container, with shock-proof and ventilation design.
Key Considerations:
This approach provides:
Lower cost per kWh
Full design flexibility
Requires strong electrical engineering and system integration knowledge
Typically longer build and commissioning time
Approach 2: Pre-Built Lithium Battery Cabinet + DC Charger Integration
For firms that require a shorter commissioning period and lower technical risk, a factory-built lithium battery cabinet simplifies the process. They feature internal BMS, EMS, and thermal management systems that are installed and ready for configuration. You just mate it to a high-performance DC charger.
Core Components:
Integrated Battery Cabinet:
Available in 100–300kWh configurations with high-voltage output, pre-installed BMS, liquid cooling, fire suppression, and EMS systems.DC Fast Charger:
Supports 60kW to 160kW, CCS2 output, OCPP1.6J protocol, user authentication, and remote monitoring.Interconnection & Trailer Integration:
The cabinet and charger are installed inside a trailer or container. Minimal wiring is needed, with safety and control wiring standardized by the manufacturer.
Key Considerations:
This approach offers:
Simplified installation and wiring
Faster commissioning time
Medium cost (higher than full DIY, lower than fully commercial units)
Easier certification and compliance
This is an ideal path for energy startups, charging service providers, or fleet operators looking to get operational quickly.
Optional Approach: Assembled from Modular Packs (Low-Cost DIY)
Some cost-sensitive users choose to build a system using smaller battery packs, for example combining 17 units of 11.7kWh packs to form a 199kWh system. These are paired with standard DC chargers. While this method significantly reduces battery sourcing costs, it demands careful design in wiring, pack balancing, and space management.
Choosing the Right Path: A Technical Comparison
| Feature | Full DIY (Modules) | Battery Cabinet + Charger |
|---|---|---|
| Total System Cost | Low | Moderate |
| Engineering Skills Required | High | Medium |
| Time to Commission | Long | Short |
| Integration Complexity | High | Low |
| Flexibility | Maximum | Moderate |
| Thermal Management Required | Custom-designed | Pre-installed |
| Certification Requirements | Manual, complex | Easier via vendors |
How Charge Ninja Can Support You
At Charge Ninja, we support both approaches through our modular hardware kits, engineering advisory, and equipment sourcing. Our capabilities include:
Lithium battery modules (air-cooled and liquid-cooled)
Integrated BESS cabinets with EMS/BMS
DC chargers (30–160kW), dual-gun output
Custom trailer/container design for mobile deployment
OCPP-compliant software integration and backend
Turnkey mobile charging systems for emergency or commercial use
If you’re looking for guidance, we can help you choose the best architecture, supply high-quality components, and provide engineering support for your build.
Conclusion: Build Smart, Scale Fast
Creating your own mobile EV-charging solution opens up vast new markets — from roadside assistance and fleets, to energy retail. Whether DIY or following the semi-integrated battery cabinet path, mobile charging ensures swift availability without the requirement for high-capacity grid connections.
We are Charge Ninja. Get in touch and let us help you design, build and deploy mobile energy storage + EV charging solutions with custom options and expert guidance.
Get Started Today
Looking to explore your mobile charging project? Contact our team for technical consultation and a tailored proposal. We provide parts, integration guidance, and turnkey solutions for global clients.
What is a mobile BESS EV charging system and why build one?
A mobile BESS EV charging system combines energy storage and DC fast charging to deliver power flexibly. It helps overcome grid limits, supports emergency needs, and enables off-grid or mobile EV charging deployments.
How can Charge Ninja help with building mobile charging systems?
Charge Ninja provides lithium batteries, integrated BESS units, DC chargers, trailer design, and backend software. We offer hardware kits and engineering support tailored to your chosen approach—modular or semi-integrated.
What are the main DIY approaches to building a mobile EV charger?
You can either assemble it yourself using battery modules and DC components for full control, or use a pre-built lithium battery cabinet with integrated systems for faster, simpler deployment and reduced technical complexity.