Engineering Case Studies

Solving Complex Power Challenges through Innovation and Precision

Client: Tier-1 AR Hardware Manufacturer

Custom-Shaped Batteries for Smart Glasses

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

Challenge

The client required a power source for lightweight AR glasses to fit within a 5mm temple arm. Standard cells were too thick (min 3mm) or lacked capacity (< 200mAh). Thermal throttling was critical near the user's temple.

Engineering Constraints

  • Max Thickness: 4mm
  • Min Capacity: 220mAh
  • Surface Temp: < 40°C under heavy load
  • Cycle Life: 1000+ cycles

Technical Solution

  • Custom Shape: Optimized internal space utilization to maximize capacity.
  • Structural Design: Innovative stacking with ultra-thin separators.
  • Thermal Management: Integrated graphite heat spreader and precision NTC monitoring.

Validation

  • Stable operation with＜6℃ temperature rise.
  • Verified 1000 cycles > 80% retention.
  • Passed compression tests for 3.8mm slim design.

Quantitative Outcomes

3.8mm
Final Thickness

Within tolerance

240mAh
Achieved Capacity

+20% vs Target

1000+
Cycle Life

80% retention

506Wh/L
Field Failures

High Energy Density

Client: Medical Device OEM

Ultra thin battery for medical device

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

Challenge

A medical wearable customer requested a custom lithium-polymer battery with 1.5mm thickness, ±0.1mm tolerance, and an irregular shape to fit a constrained enclosure. The battery also needed to provide 24mAh at 3.85V and comply with multiple regulatory certifications.

Technical Challenges

  • Excessive thinness of the battery may result in short folding edges
  • Short folding edges can compromise sealing, increasisng the risk of leakage
  • The battery is prone to swelling under certain conditions
  • Sterilization: Resistant to cleaning agents

Technical Solution

  • Optimized edge design to maximize sealing area without increasing thickness.
  • High-strength flexible packaging and enhanced sealing process to prevent leakage.
  • Material and structural improvementsto reduce swelling and maintain battery integrity.

Validation

  • Battery maintained its shape with no bulging during normal use.
  • Sealing remained intact, with no leakage observed in testing.
  • Capacity verified at 24mAh, 3.85V.

Quantitative Outcomes

1.5mm
Achieved thickness

With ±0.1mm tolerance

8
Certifications

Strict certification compliance

1000+
Cycles

Long service life

24mAh
Capacity

Successfullu met

Wearable Tech Startup

Custom Curved Battery Design

Custom curved battery design for wearable technology - flexible battery solution

Initial Requirements

A smart ring manufacturer required a highly compact battery to fit the limited internal space of their device. The battery needed a 17mAh capacity and a form factor that perfectly conformed to the ring's design.

Key Challenges

  • Curved battery manufacturing complexity
  • Maintaining performance in curved form
  • Extremely limited internal space
  • Deliver sufficient 17mAh capacity in a tiny form factor

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

17mAh
Target Capacity

Successfully met

1.7mm
Thickness

Achieved

30%
Time Saved

Time to market reduced

Wireless Charger Company

High Energy Density Battery Design

Custom curved battery design for wearable technology - flexible battery solution

Initial Requirements

A wireless-charger manufacturer needed a high-energy-density battery that could fit their compact circular design. They required a 4000mAh, round-shaped battery to match the internal structure of the device. We developed a custom solution that delivered the required capacity and performance while fitting perfectly into the product's form factor.

Key Challenges

  • The battery must fit into a compact round shape(Φ65 × T6.0 mm)
  • Achieving 4000mAh within this size demands ultra-high energy density(＞700 Wh/L)
  • Choosing materials that can safely support higher electrode loading
  • Ensuring precise dimensions so the round cell fits perfectly

Technical Challenges

  • The Si-C anode expands during cycling, creating risks of swelling and capacity loss.
  • Large volume changes make it hard to maintain a stable SEI layer.
  • The electrode must remain mechanically stable under repeated expansion.
  • High energy density must be achieved without sacrificing cycle performance.

Our Solution

  • Optimized silicon particle size and distribution to reduce expansion and improve stability.
  • High-accuracy coating and stacking ensured tight dimensional tolerances.
  • Electrolyte composition and formation cycles were adjusted to form a uniform, durable SEI layer.
  • Achieved high capacity without compromising long-term performance.

Final Results

4000mAh
Target Capacity

Successfully met

778Wh/L
Energy Density

Ensure long usage time

Round Battery
Target Dimension

Maximize space utilization

500+ times
Cycle Life

Long service time

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