Compact 48V UAV Power Management

I’m building a shared Power Management Unit to run off a 12 S (≈ 48 V nominal) lithium-ion battery pack used across my autonomous UAVs and small UGVs. The board has to fit inside a 86 mm × 55 mm envelope, survive the vibration and temperature swings of flight, and be simple enough for repeat production through JLCPCB’s turnkey assembly service.

Core functionality
• High-voltage distribution with robust inrush-/over-current and reverse-polarity protection
• Multiple, well-isolated regulated rails for avionics, companion computers, payloads and SAT-COM gear
• Integrated buck/boost conversion and overall power-path management for maximum efficiency
• On-board current, voltage and thermal sensing routed to a telemetry header/UART so the flight controller can log live power data
• Individually switchable power domains that can be enabled or disabled remotely via a logic-level control line (GPIO, CAN, or similar)
• Clearly reserved connector space and headers for future expansion, keeping the architecture clean and modular so new features won’t trigger a complete redo of the layout

What I need from you
– Full schematic capture and PCB layout ready for JLCPCB (Gerber + pick-and-place, stack-up notes, impedance requirements if any)
– A concise, production-ready BOM that sticks to footprints and part numbers JLCPCB can source or alternates that are drop-in compatible
– Thermal analysis / copper pour recommendations to ensure regulators and FETs stay within safe junction temperature under continuous 48 V input
– Brief design documentation explaining how each rail is protected, where telemetry is tapped, and how additional daughter-cards could be added later

I’m prioritising reliability, straightforward manufacturing and a layout that can be serviced in the field. If you’ve already created compact power boards for drones, EVs or robotics — especially anything running off 10–14 S packs — your experience will be a perfect fit. Let’s discuss component selection, connector style, and any test firmware you might need to validate the board once the first prototypes come back from the fab.