Case Studies

Real solutions for real challenges - proven results from our custom battery projects

AR Glasses Manufacturer

Ultra-Thin Battery Solution

Ultra-thin battery solution for AR glasses - custom shaped lithium battery

Initial Requirements

AR glasses manufacturer needed ultra-thin battery (target: 1.2mm) with 800mAh capacity to fit into temple arm. Required 3.7V operation with 1C discharge rate.

Key Challenges

  • Extremely limited space in temple arm
  • Heat dissipation concerns during operation
  • Maintaining capacity at reduced thickness
  • Long cycle life requirement (500+ cycles)

Technical Challenges

  • Electrode thickness optimization
  • Thermal management design
  • Custom curved shape to fit temple
  • Protection circuit miniaturization

Our Solution

  • Developed custom ultra-thin electrode structure
  • Implemented advanced thermal management layer
  • Designed curved battery matching temple geometry
  • Integrated compact protection circuit

Final Results

18%
Thickness Reduction

From 1.46mm to 1.2mm

6°C
Temperature Reduction

During operation

800mAh
Capacity Maintained

Target capacity achieved

600+
Cycle Life

Exceeded requirement

Medical Device Company

High-Temperature Performance Battery

High-temperature performance battery for medical devices - custom lithium battery solution

Initial Requirements

Medical device company required battery for portable equipment operating in elevated temperature environments (up to 55°C). Needed 1200mAh capacity with extended cycle life.

Key Challenges

  • Performance degradation at high temperatures
  • Safety concerns in medical applications
  • Long-term reliability requirements
  • Compliance with medical device standards

Technical Challenges

  • Electrolyte formulation for high temperature
  • Thermal stability optimization
  • Capacity retention at elevated temperatures
  • Safety circuit design for medical use

Our Solution

  • Developed high-temperature electrolyte formula
  • Optimized cell structure for thermal management
  • Implemented enhanced safety protection
  • Conducted comprehensive testing and validation

Final Results

40%
Battery Life Extended

At operating conditions

100%
Safety Certifications

ISO, medical standards passed

>90%
Capacity Retention

After 500 cycles at 55°C

0
Safety Incidents

In field deployment

Wearable Tech Startup

Custom Curved Battery Design

Custom curved battery design for wearable technology - flexible battery solution

Initial Requirements

Wearable tech startup needed curved battery to fit unique wristband design. Required 300mAh capacity in curved form factor with flexible connection.

Key Challenges

  • Curved battery manufacturing complexity
  • Maintaining performance in curved form
  • Flexible connection requirements
  • Cost-effective production solution

Technical Challenges

  • Electrode bending without damage
  • Curved cell assembly process
  • Flexible connector integration
  • Production scalability

Our Solution

  • Developed specialized curved stacking process
  • Designed flexible electrode structure
  • Integrated custom flexible connector
  • Optimized production process for scalability

Final Results

95%
Space Utilization

Maximum efficiency achieved

300mAh
Target Capacity

Successfully met

25%
Cost Reduction

Production optimized

30%
Time Saved

Time to market reduced

Have a Similar Challenge?

Our engineering team can help solve your custom battery requirements

Discuss Your Project