BluePower is a battery manufacturer with its own production facility, specializing in custom battery solutions built around specific project requirements rather than standard cell limitations.
Many of our projects involve uniquely shaped, curved, or ultra-thin batteries, as well as solutions engineered for challenging environments such as low-temperature operation. Our focus is always the same: designing batteries that integrate naturally into the product, instead of forcing the product to adapt to the battery.
In real-world applications, we work more as a development partner than a simple supplier. By evaluating product structure, usage conditions, and critical constraints, we help turn design concepts into battery solutions that are both practical and scalable for mass production.
From cell design and material selection to manufacturing and performance testing, every step is handled in-house to ensure consistency, reliability, and long-term performance.
Custom-Shaped Battery Solutions
We can customize batteries into various shapes. We can maximize the use of device space without changing your product design, which improves energy density and delivers a better battery life experience for users.
- With stacking technology, we can greatly avoid the hollow gaps and rounded dead corners caused by winding technology showed in the below picture, resulting in higher space utilization and high energy density up to 350Wh/Kg.
- In addition, the stacked structure has no bending stress and expands evenly during charging and discharging. It has a longer cycle life than wound batteries. Our batteries can retain more than 80% of their capacity after 1000 charge-discharge cycles.
- Stacked batteries have balanced current distribution and even heat generation, without the risk of electrode sheet wrinkling that exists in wound batteries, so they are much safer.
Besides custom shapes, we can also develop high-voltage batteries according to your needs, with a maximum voltage of 4.5V. We can also meet your discharge rate requirements.
For dimensions, our shaped batteries support a wide range of customization to meet the design needs of products with different sizes and structural constraints:
- Thickness: 0.6 mm – 10 mm
- Width: 5 mm – 65 mm
- Length: 5 mm – 65 mm
Curved Battery Solutions for Smart Rings
The success of a smart ring largely depends on user experience, and battery technology plays a key role in shaping that experience. In practice, smart ring batteries face several critical challenges:
- Extreme space limitations
The ring form factor leaves very limited curved space for the battery, while still requiring the highest possible energy density. - The trade-off between performance and runtime
Users expect long battery life, but smaller batteries mean limited capacity. At the same time, continuous sensing and frequent data collection place a heavy load on power consumption. - Strict safety and reliability requirements
As a device worn on the body 24/7, a smart ring battery must remain safe and stable under different environments, with no room for compromise.
Our Technology Approach
To address these challenges, we apply a stacked cell process combined with native curved forming. The cells are stacked first and then hot-pressed into a curved shape, rather than mechanically bent. This avoids internal mechanical stress and reduces the risk of micro short circuits caused by bending, resulting in longer cycle life and improved safety. The process also helps maintain better consistency during mass production.
We also develop custom silicon-carbon anode materials. Compared with traditional graphite anodes, this approach significantly increases capacity and volumetric energy density, while maintaining stable high-rate discharge performance and long cycle life.
In addition, every battery goes through full-process testing to ensure long-term safety and reliability for continuous, on-body use.
Ongoing Development
We continue to invest in the development of silicon-carbon anode materials and explore next-generation material systems with higher capacity. Our goal is to increase battery capacity within the same size constraints, enabling longer runtime and a better user experience for smart ring devices.
5mm Ultra Narrow Battery Solutions
BluePower’s ultra-narrow batteries are developed using specialized design and manufacturing techniques to deliver stable performance, consistent quality, and reliable safety. With a minimum width of 5 mm, these batteries can be customized to fit extremely limited internal spaces, making them well suited for compact electronic devices—especially modern smart glasses.
Today, leading smart glasses brands rarely promote battery capacity as a headline specification. Instead, they focus on user experience outcomes, such as:
- A natural, comfortable wearing feel
- All-day wear without pressure or fatigue
- Seamless, low-awareness operation during use
Meeting these expectations requires a battery that is lightweight yet energy-dense, capable of fitting into the narrow temple arms without changing the overall frame shape. At the same time, thermal stability and heat control are critical to ensure comfort during prolonged use.
Key Advantages of Our Ultra-Narrow Battery Solutions
A balanced combination of appearance, comfort, and battery life
The result is a smart glasses design that maintains a slim profile while still delivering reliable all-day performance.
Improved space efficiency
The battery is shaped to follow the internal contours of the temple arms, reducing wasted space and maximizing usable energy within a limited volume.
Greater design freedom
Industrial designers do not need to compromise on frame thickness, curvature, or weight balance due to battery constraints, allowing the design to focus on wearing comfort.
0.6mm Ultra Thin Battery Solutions
Ultra-thin batteries place much higher demands on cell design and manufacturing processes.
- Both the positive and negative electrode layers must be extremely thin, which requires very high coating accuracy to ensure uniform thickness.
- Micron-level ultra-thin separators are also required, with strict control over mechanical strength and flatness to prevent internal short circuits.
- In addition, cell packaging becomes significantly more challenging as thickness decreases.
Our Manufacturing Approach
For ultra-thin batteries, we do not rely on standard cell templates. Instead, the cell structure is designed specifically around the target thickness of each project. Starting from the final thickness requirement, we work backward layer by layer to develop a customized internal structure that balances performance, reliability, and manufacturability.
To support this approach, we have built a dedicated supply chain that focuses on materials suitable for ultra-thin battery designs. Only materials that meet the mechanical and process requirements of thin cells are selected.
From coating and stacking to packaging and final assembly, every step is managed with careful micro-stress control. This end-to-end process discipline allows us to maintain structural stability even at very small thicknesses.
As a result, we have achieved stable mass production of ultra-thin batteries, ensuring consistent quality and repeatable performance across every production batch.
-40℃ Low Temp Battery Solutions
Low temperatures have a negative impact on lithium battery performance, affecting capacity, cycle life, internal resistance, and charge–discharge efficiency. However, these challenges are not impossible to overcome. Through targeted optimization of electrolyte formulation, electrode materials, and cell structure, BluePower has developed lithium battery solutions designed specifically for low-temperature environments.
These batteries are built to support reliable operation in cold weather for applications such as drones and robotics, where stable power output is critical under harsh conditions.
Proven Low-Temperature Performance
Our batteries maintain stable performance at low temperatures:
- At –40°C with a 0.5C discharge rate, the battery retains over 60% discharge efficiency
- At –30°C, the battery can deliver approximately 80% of its rated capacity
- Operating temperature range: –40°C to 60°C
In addition, the batteries have passed multiple safety and compliance certifications, including UL, CE, and UN standards, ensuring reliability and safety in demanding environments.
High Energy Density Silicon Carbon Battery Solutions
The performance of graphite anodes has reached its practical limits. Silicon, on the other hand, can store significantly more lithium ions than graphite. However, pure silicon has clear drawbacks: it expands dramatically during charging, which leads to rapid capacity fade and reduced cycle life. To address this, the industry approach is to use carbon materials to encapsulate, buffer, and support silicon.
Our in-house developed silicon–carbon battery technology is designed to balance higher capacity with long-term stability and has achieved the following improvements:
- Approximately 20% higher capacity compared with conventional lithium batteries
- Volumetric energy density up to 778 Wh/L, around 25% higher than graphite-based batteries
- Proprietary low-expansion silicon–carbon material system, developed internally
In mass production, we carefully control the silicon content and combine it with appropriate cell structures and manufacturing processes, such as stacked cell design. With this approach, silicon–carbon batteries can still deliver stable and reliable cycle life, comparable to that of traditional lithium-ion batteries, while offering higher energy density.
Conclusion
Standard batteries are still a reliable choice for many mature products. But when a device has an unusual internal structure or operates in demanding environments, the battery often becomes a key factor in whether the product can be built—and whether it can perform well.
BluePower offers a range of battery solutions, including custom-shaped, curved, ultra-narrow, ultra-thin, low-temperature, and high energy density silicon-carbon batteries. The core idea behind all of them is simple: the battery should adapt to your product, not force changes to your product design.
If your project is facing challenges such as:
- Battery size or shape does not fit the product structure
- Difficulty balancing runtime, safety, and environmental performance
- Repeated trial and error with standard batteries slowing down development
We welcome you to share your specific requirements with us. Based on your product structure, application scenario, and performance goals, we can evaluate and provide custom battery solutions that are practical, manufacturable, and ready for mass production.
