Now that I have a working prototype, I can show what it looks inside.
Hardware main features:
1. Extra compact design. This is a 24F controller made to fit a standard Infienon 18F enclosure.
2. Power components rated up to 150v.
3. Split control and power board design with power stage built on aluminum substrate PCB. This ensures very good (if not the best) heat dissipating interface to a heatsink.
4. "Legless" mosfet package used which means better control over parasitic inductance and no hard terminal limitations like 70A in To-220, for example.
5. The control logic is fully isolated from the power stage which allows running higher voltages and currents reliably (extra cost is the downside but it's worth it).
What's implemented/tested:
1. All major VESC firmware features work.
2. A few motors were tested to pass detection in FOC mode.
3. Tested under load with battery currents up 100A and voltages up to 106v. All works well including variable regen.
4. Bluetooth dashboard/telemetry integration with PV app for Android and iOS (speed, voltage, current, distance, temperatures, etc.)
To do in the near future:
Add one button motor detection/setup to the PV app; add settings for batt, phase current, voltage, etc. to support different battery configurations.