EU Adds Exemptions To User-Serviceable Batteries Rules

July 17, 2026 by Maya Posch 70 Comments

Built-in batteries put a timebomb inside devices, with especially the calendar aging feature of Li-ion chemistries setting a hard limit on when you’ll have to toss the device or figure out a way to replace the battery somehow. Here the EU’s Battery Regulation policy with the 2027 implementation of the user-serviceable battery requirement provided a lot of hope. Now six new categories of exemptions are diminishing what could have been a bonanza of easy repairability.

Most notable here are smartwatches, fitness trackers, wireless earbuds and other so-called ‘wet devices’, which as GSMArena also notes is an area where having a user-replaceable battery might affect features like being water-resistant. Something which is also relevant for e.g. outdoor wireless speakers. There’s also a new exemption for smartphones, where if its battery retains at least 83% of its original capacity after 500 charge cycles, battery replacement has to be only replaceable by professionals. Which is probably code for ‘glue, hotplates and prying tools’.

Considering just how daft of an idea built-in batteries are, this is somewhat disappointing to see. While it’s understandable that ‘wet devices’ get such broad exemptions, it should be noted here that advanced technologies like gaskets are neither complicated nor expensive. You can even hand the average user a tube of RTV silicone and let them go to town on a part in the happy knowledge that there’s never such a thing as ‘too much’ RTV silicone.

It is likely that there was some pressure from the industry on the EU to not change too much, but at the very least us happy few in the EU will be getting a new Nintendo Switch 2 with easily replaced battery in both the main unit and its controllers. For the average rechargeable device you keep kicking around the house this should also still apply as long as its manufacturer cannot squeeze it into one of these exemption categories.

The Right to Repair battles shall continue.

ChargeCap Helps Your Batteries Last Longer By Limiting Charge Level

May 14, 2026 by Donald Papp 22 Comments

If you want to maximize the life of your lithium-ion batteries, proper storage voltage is critical. That is, don’t store them empty, and don’t store them completely full either. “Almost fully charged” is a sweet spot for occasional-use devices. Sadly, this is easier said than done. While many devices use integrated rechargeable batteries these days, most provide no method of limiting charge level. That’s where [DaverDavid]’s ChargeCap comes in.

By sampling charge current and disconnecting when it drops to 50 percent of peak, charging is reliably stopped when the target device is 80 to 90 percent charged, regardless of cell count or capacity.

ChargeCap sits between a USB charger and target device, disconnecting when it detects that recharging is 80 to 90 percent complete. This is particularly useful for maximizing the cell life of devices that see only intermittent use.

The way ChargeCap does this is clever, and relies on the fact that all lithium-ion charging curves look the same regardless of cell capacity or cell count. Charge current remains at pretty much the same level for most of the charging process, but tapers off quickly (and in a linear fashion) as cells approach their maximum capacity. That’s because charging a battery is a lot like blowing up a balloon: the first breaths are easy, but once the balloon fills out, every breath needs to push harder than the last.

ChargeCap works by sampling the peak charge current at the beginning of the charge cycle, then detecting when it drops below 50 percent of peak, at which point charging is stopped. The result is a device that reliably charges to 80 to 90 percent of capacity, and no more. ChargeCap uses an ESP32-C3 and a small OLED display that, as a nice touch, inverts colors to signal charge completion. Design files and code are at the GitHub repository.

Lithium-ion cells are fantastic devices, so flesh out your knowledge by reading [Arya Voronova]’s primer on designing them into your own projects, or a more in-depth explanation of how they work.

Why Solid State Batteries Short

April 27, 2026 by Al Williams 15 Comments

Solid state batteries, we are told, are the new hot battery technology that will replace lithium-ion batteries. Soon. Not that we haven’t heard that before. One reason it isn’t dominating the market today is that it’s prone to short circuits during charging. [Dr. Yuwei Zhang and others have published a paper detailing why the shorts happen, which could lead to strategies to improve the technology.

Solid state batteries employ a solid electrolyte and a lithium anode. It is known that, sometimes, lithium metal from the anode forms dendrites that penetrate the ceramic electrolyte and cause it to crack. This is somewhat of a mystery as the lithium is a soft metal: to quote [Zhang], “like a gummy bear”.

There were two leading hypotheses for the observations. [Zhang’s] team showed that hydrostatic stress made the lithium dendrites act like a water jet, enabling them to penetrate the hard ceramic.

There is still work to figure out what to do about it, but understanding the root cause is certainly a step in the right direction. We’ve looked at these batteries before. We’ve also seen how changing the anode construction might help with the problem.

Performing An Autopsy On 15 Dead Battle Born LFP Batteries

February 16, 2026 by Maya Posch 21 Comments

More molten plastic spacers between the bus bar and terminal. (Credit: Will Prowse)

Because size matters when it comes to statistics, [Will Prowse] decided to not just bank on his handful of failed Battle Born LFP batteries when it came to documenting their failure modes. Instead he got a whole gaggle of them from a viewer who had experienced failures with their Battle Born LFP batteries for an autopsy, adding a total of 15 samples to the data set.

Interestingly, the symptoms of these dead batteries are all over the place, from a refusal to charge, some have the overheating terminal, some do not show any sign of life, others have charged cells but a non-responsive BMS, etc. As [Will] notes, it’s important to test batteries with a load and a charger to determine whether they are functional not just whether you can measure a charge.

Although some of the batteries still showed enough signs of life to be put aside for some load testing, the remaining ones were cut open to check their insides. This revealed the typical molten plastic at the terminals, but also a lot of very loose connections for the internal wiring. Another battery showed signs of corrosion inside, which could be due to either moisture intrusion or a cell having leaked its electrolyte.

While the full results will hopefully be released soon, the worrying thing about this latest batch of Battle Born LFP batteries is that they span quite a few years, with one being from 2018. Although it’s comforting that not every one of these batteries is necessarily going to catch on fire within its approximate 8-year lifespan, a lot seems to depend on exactly how you load and charge them, as [Will] is trying to figure out with the upcoming load testing. With the unit that he recently purchased for testing it turned out that lower currents actually made the melting problem much worse.

Between this video and the much awaited follow-up, [Will] actually got his hands on a troubled 300A-rated industrial Battle Born battery. During testing that one actually failed violently with a cell venting and the loose BMS rattling around in the case.

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Why Sodium-Ion Batteries Are Terrible For Solar Storage

October 30, 2025 by Maya Posch 84 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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Have Li-ion Batteries Gone Too Far?

March 13, 2025 by Navarre Bartz 85 Comments

The proliferation of affordable lithium batteries has made modern life convenient in a way we could only imagine in the 80s when everything was powered by squadrons of AAs, or has it? [Ian Bogost] ponders whether sticking a lithium in every new device is really the best idea.

There’s no doubt, that for some applications, lithium-based chemistries are a critically-enabling technology. NiMH-based EVs of the 1990s suffered short range and slow recharge times which made them only useful as commuter cars, but is a flashlight really better with lithium than with a replaceable cell? When household electronics are treated as disposable, and Right to Repair is only a glimmer in the eye of some legislators, a worn-out cell in a rarely-used device might destine it to the trash bin, especially for the less technically inclined.

[Bogost] decries “the misconception that rechargeables are always better,” although we wonder why his article completely fails to mention the existence of rechargeable NiMH AAs and AAAs which are loads better than their forebears in the 90s. Perhaps even more relevantly, standardized pouch and cylindrical lithium cells are available like the venerable 18650 which we know many makers prefer due to their easy-to-obtain nature. Regardless, we can certainly agree with the author that easy to source and replace batteries are few and far between in many consumer electronics these days. Perhaps new EU regulations will help?

Once you’ve selected a battery for your project, don’t forget to manage it if it’s a Li-ion cell. With great power density, comes great responsibility.

Hackaday Links: October 27, 2024

October 27, 2024 by Dan Maloney 14 Comments

Problem solved? If the problem is supplying enough lithium to build batteries for all the electric vehicles that will be needed by 2030, then a new lithium deposit in Arkansas might be a resounding “Yes!” The discovery involves the Smackover Formation — and we’ll be honest here that half the reason we chose to feature this story was to be able to write “Smackover Formation” — which is a limestone aquifer covering a vast arc from the Rio Grande River in Texas through to the western tip of the Florida panhandle. Parts of the aquifer, including the bit that bulges up into southern Arkansas, bear a brine rich in lithium salts, far more so than any of the brines currently commercially exploited for lithium metal production elsewhere in the world. Given the measured concentration and estimated volume of brine in the formation, there could be between 5 million and 19 million tons of lithium in the formation; even at the lower end of the range, that’s enough to build nine times the number of EV batteries needed.

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