DIY Powerwall Blows Clouds, Competition Out Of The Water

November 6, 2025 by Tyler August 31 Comments

Economists have this idea that we live in an efficient market, but it’s hard to fathom that when disposable vapes are equipped with rechargeable lithium cells. Still, just as market economists point out that if you leave a dollar on the sidewalk someone will pick it up, if you leave dollars worth of lithium batteries on the sidewalk, [Chris Doel] will pick them up and build a DIY home battery bank that we really hope won’t burn down his shop.

The Powerwall-like arrangement uses 500 batteries salvaged from disposable vapes. His personal quality control measure while pulling the cells from the vapes was to skip any that had been discharged past 3 V. On the other hand, we’d be conservative too if we had to live with this thing, solid brick construction or not.

That quality control was accomplished by a clever hack in and of itself: he built a device to blow through the found vapes and see if they lit up. (That starts at 3:20 in the vid.) No light? Not enough voltage. Easy. Even if you’re not building a hoe powerbank, you might take note of that hack if you’re interested in harvesting other people’s deathsticks for lithium cells. The secret ingredient was the pump from a CPAP machine. Actually, it was the only ingredient.)

In another nod to safety, he fuses every battery and the links between the 3D printed OSHA unapproved packs. The juxtoposition between janky build and careful design nods makes this hack delightful, and we really hope [Chris] doesn’t burn down his shed, because like the cut of his jib and hope to see more hacks from this lad. They likely won’t involve nicotine-soaked lithium, however, as the UK is finally banning disposable vapes.

In some ways, that’s a pity, since they’re apparently good for more than just batteries — you can host a website on some of these things. How’s that for market efficiency?

Continue reading “DIY Powerwall Blows Clouds, Competition Out Of The Water” →

Lithium-Ion Batteries: WHY They Demand Respect

November 4, 2025 by Arya Voronova 62 Comments

This summer, we saw the WHY (What Hackers Yearn) event happen in Netherlands, of course, with a badge to match. Many badges these days embrace the QWERTY computer aesthetic, which I’m personally genuinely happy about. This one used 18650 batteries for power, in a dual parallel cell configuration… Oh snap, that’s my favourite LiIon cell in my favourite configuration, too! Surely, nothing bad could happen?

Whoops. That one almost caught me by surprise, I have to shamefully admit. I just genuinely love 18650 cells, in all glory they bring to hardware hacking, and my excitement must’ve blindsided me. They’re the closest possible entity to a “LiIon battery module”, surprisingly easy to find in most corners of this planet, cheap to acquire in large quantities, easy to interface to your projects, and packing a huge amount of power. It’s a perfect cell for many applications I and many other hackers hold dear.

Sadly, the 18650 cells were a bad choice for the WHY badge, for multiple reasons at once. If you’re considering building a 18650-based project, or even a product, let me show you what exactly made these cells a bad fit, and how you might be able to work around those limitations on your own journey. There’s plenty of technical factors, but I will tell you about the social factors, because these create the real dealbreaker here. Continue reading “Lithium-Ion Batteries: WHY They Demand Respect” →

Why Sodium-Ion Batteries Are Terrible For Solar Storage

October 30, 2025 by Maya Posch 82 Comments

These days just about any battery storage solution connected to PV solar or similar uses LiFePO4 (LFP) batteries. The reason for this is obvious: they have a very practical charge and discharge curve that chargers and inverters love, along with a great round trip efficiency. Meanwhile some are claiming that sodium-ion (Na+) batteries would be even better, but this is not borne out by the evidence, with [Will Prowse] testing and tearing down an Na+ battery to prove the point.

The Hysincere brand battery that [Will] has on the test bench claims a nominal voltage of 12 V and a 100 Ah capacity, which all appears to be in place based on the cells found inside. The lower nominal voltage compared to LFP’s 12.8 V is only part of the picture, as can be seen in the OCV curve. Virtually all of LFP’s useful capacity is found in a very narrow voltage band, with only significant excursions when reaching around >98% or <10% of state of charge.

What this means is that with existing chargers and inverters, there is a whole chunk of the Na+ discharge curve that’s impossible to use, and chargers will refuse to charge Na+ batteries that are technically still healthy due to the low cell voltage. In numbers, this means that [Will] got a capacity of 82 Ah out of this particular 100 Ah battery, despite the battery costing twice that of a comparable LFP one.

Yet even after correcting for that, the internal resistance of these Na+ batteries appears to be significantly higher, giving a round trip efficiency of 60 – 92%, which is a far cry from the 95% to 99% of LFP. Until things change here, [Will] doesn’t see much of a future for Na+ beyond perhaps grid-level storage and as a starter battery for very cold climates.

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Tiny UPS Keeps WiFi Online

October 24, 2025 by Bryan Cockfield 29 Comments

For any mission-critical computer system, it’s a good idea to think about how the system will handle power outages. At the very least it’s a good idea to give the computer enough time to gracefully shut down if the power outage will last for an indefinite time. But for extremely critical infrastructure, like our home Wi-Fi, we might consider a more long-term battery backup that can let us get through the longest of power outages.

Part of why this project from [Next Builder] works so well is that most off-the-shelf routers don’t actually use that much energy. Keeping that and a modem online when the power is out only requires a few lithium batteries. To that end, three lithium ion cells are arranged in series to provide the router with between 9 and 12 volts, complete with a battery management system (BMS) to ensure they aren’t over- or under-charged and that they are balanced. The router plugs directly into a barrel jack, eliminating any switching losses from having to use an inverter during battery operation.

While [Next Builder] is a student who lives in an area with frequent interruptions to the electricity supply, this does a good job of keeping him online. If you’re planning for worse or longer outages, a design like this is easily adapted for more batteries provided the correct BMS is used to keep the cells safely charged and regulated. You can also adapt much larger UPS systems to power more of your home’s electrical system, provided you can find enough batteries.

Lumafield Shows Why Your Cheap 18650 Cells Are Terrible

September 29, 2025 by Jenny List 38 Comments

Lithium-ion cells deliver very high energy densities compared to many other battery technologies, but they bring with them a danger of fire or explosion if they are misused. We’re mostly aware of the battery conditioning requirements to ensure cells stay in a safe condition, but how much do we know about the construction of the cells as a factor? [Lumafield] is an industrial imaging company, and to demonstrate their expertise, they’ve subjected a large number of 18650 cells from different brands to a CT scan.

The construction of an 18650 sees the various layers of the cell rolled up in a spiral inside the metal tube that makes up the cell body. The construction of this “jellyroll” is key to the quality of the cell. [Lumafield’s] conclusions go into detail over the various inconsistencies in this spiral, which can result in cell failure. It’s important that the edges of the spiral be straight and that there is no electrode overhang. Perhaps unsurprisingly, they find that cheap no-name cells are poorly constructed and more likely to fail, but it’s also interesting to note that these low-quality cells also have fewer layers in their spiral.

We hope that none of you see more of the inside of a cell in real life than you have to, as they’re best left alone, but this report certainly sheds some light as to what’s going on inside a cell. Of course, even the best cells can still be dangerous without protection.

Calculator Battery Mod Lets You Go The Distance

September 23, 2025 by Dan Maloney 23 Comments

Disposable batteries seem so 1990s. Sure, it’s nice to be able to spend a couple of bucks at the drugstore and get a flashlight or TV remote back in the game, but when the device is a daily driver, rechargeable batteries sure seem to make more financial sense. Unfortunately, what makes sense to the end user doesn’t always make sense to manufacturers, so rolling your own rechargeable calculator battery pack might be your best option.

This slick hack comes to us from [Magmabow], who uses a Casio FXCG50 calculator, a known battery hog. With regular use, it goes through a set of four alkaline AA batteries every couple of months, which adds up quickly. In search of a visually clean build, [Magmabow] based the build around the biggest LiPo pillow-pack he could find that would fit inside the empty battery compartment, and planned to tap into the calculator’s existing USB port for charging. A custom PCB provides charging control and boosts the nominal 3.7-volt output of the battery to the 5-ish volts the calculator wants to see. The PCB design is quite clever; it spans across the battery compartment, with its output feeding directly into the spring contacts normally used for the AAs. A 3D-printed insert keeps the LiPo and the PCB in place inside the battery compartment.

Almost no modifications to the calculator are needed, other than a couple of bodge wires to connect the battery pack to the calculator’s USB port. The downside is that the calculator’s battery status indicator won’t work anymore since the controller will just shut the 5-volt output down when the LiPo is discharged. It seems like there might be a simple fix for that, but implementing it on such a small PCB could be quite a challenge, in which case a calculator with a little more room to work with might be nice. Continue reading “Calculator Battery Mod Lets You Go The Distance” →

Reverse-Engineering The Milwaukee M18 Diagnostics Protocol

September 14, 2025 by Maya Posch 18 Comments

As is regrettably typical in the cordless tool world, Milwaukee’s M18 batteries are highly proprietary. Consequently, this makes them a welcome target for reverse-engineering of their interfaces and protocols. Most recently the full diagnostic command set for M18 battery packs were reverse-engineered by [ToolScientist] and others, allowing anyone to check useful things like individual cell voltages and a range of statistics without having to crack open the battery case.

These results follow on our previous coverage back in 2023, when the basic interface and poorly checksummed protocol was being explored. At the time basic battery management system (BMS) information could be obtained this way, but now the range of known commands has been massively expanded. This mostly involved just brute-forcing responses from a gaggle of battery pack BMSes.

Interpreting the responses was the next challenge, with responses like cell voltage being deciphered so far, but serial number and the like being harder to determine. As explained in the video below, there are many gotchas that make analyzing these packs significantly harder, such as some reads only working properly if the battery is on a charger, or after an initial read.

Continue reading “Reverse-Engineering The Milwaukee M18 Diagnostics Protocol” →