The Unreasonable Power Density Of Lithium-Ion

March 21, 2026 by Elliot Williams 68 Comments

We’re all used to it by now, but I’d just like to reflect on how insanely power-packed lithium ion batteries are, and everything that’s afforded us. I’m trying to think of a gadget, a hobby, or nearly anything in my house that’s not touched by the battery chemistry.

I’m looking at my portable wireless keyboard in front of me, with a LiPo pack inside. Oddly enough, I’m charging it with a LiPo-based power bank, simply because the cable to the nearest USB-C adapter is too short. A gaming console, cell phone, and a DSLR camera are all within arms reach and powered with lithium.

It’s not just consumer stuff either. I fly FPV quads and airplanes for fun when I can, and of course those are made entirely possible by the combination of smaller brushless DC motors and their drivers, and the high-power-density LiPo packs that power them. For field recharging, I have a huge self-made LiIon pack that can keep them all in the air all day. These days, LiPo and LiIon tech is the heart of hacker projects big and small. Heck, we even powered this year’s Hackaday Supercon badge with a LiPo that allowed it to run all weekend on a charge for many folks, where in the past swapping out AAs during the event was commonplace.

The application that still blows my mind is that we recently got a solar installation on our roof, which means a huge LiFePO battery in the basement. And while it’s one thing to power noisy little quads on the battery tech, it somehow seems another to power our entire house, for multiple hours per day, from a battery. Granted it’s not a couple of AAA cells in a little black plastic box, but it’s simply amazing to run a washing machine, the fridge, the stove, and even the heating off of what amounts to a battery pack.

Of course, I’m aware of the costs of producing the cells, both in terms of money and the environmental damage. It’s not a free lunch, and I’m looking forward to both cleaner and cheaper energy storage chemistries in the future. But for now, I’m still in awe of the many options that lithium-based battery chemistry has brought us. May your pillows remain non-spicy!

Limiting Battery Risk On Repurposed Smartphones With PostmarketOS

February 1, 2026 by Lewin Day 28 Comments

PostmarketOS is a Linux distribution specifically designed for those who wish to repurpose old smartphones as general-use computers, to a degree. This can be a great way to reuse old hardware. However, for [Bry50], it was somewhat discomforting leaving the phone’s aging lithium battery perpetually on charge. A bit of code was thus whipped up to provide a greater measure of safety.

The concept is simple enough—lithium batteries are at lower risk of surprise combustion events if they’re held at a lower state of charge. To this end, [Bry50] modified the device tree in PostmarketOS to change the maximum charge level. Apparently, maximum charge was set at a lofty 4.4V (100%), but this was reconfigured to a lower level of 3.8V, corresponding to a roughly 40-50% state of charge. The idea is that this is a much healthier way to maintain a battery hooked up to power for long periods of time. There’s one small hitch—the system will get confused if the battery voltage is higher than the 3.8 V setpoint when switching over. It’s thus important to let the device discharge to a lower level if you choose to make this change.

It’s a neat mod that both increases safety, but keeps the battery on hand to let the system ride through minor power outages. If you’re new to the world of repurposing old smartphones, fear not. [Bryan] also has a tutorial on getting started with PostmarketOS for the unfamiliar. If you’re working on your own projects in this space, we’d love to hear about them—so get on over to the tipsline!

DIY Powerwall Blows Clouds, Competition Out Of The Water

November 6, 2025 by Tyler August 34 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?

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Making The World’s Smallest E-Bike Battery

September 1, 2025 by Fenix Guthrie 25 Comments

Often times, e-bikes seek to build the biggest battery with the most range. But what if you want to take a couple lunch loops on your bike and only need 20 minutes of charge? That’s [Seth] from Berm Peak set out to find out with his minuscule Bermacell battery.

The battery is made from only 14 18650s, this tiny 52V batty is nearly as small an e-bike battery as can be made. Each cell is 3000 mAh making a total battery capacity of 156 Wh. All the cells were welded in series with an off the shelf BMS and everything was neatly packaged in an over-sized 3D printed 9V battery case. [Seth] plans to make another smaller battery with less then 100 Wh of capacity so he can take it on a plane, so stay tuned for more coverage!

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Is It Time To Retire The TP4056?

August 8, 2025 by Tyler August 30 Comments

The TP4056 is the default charge-controller chip for any maker or hacker working with lithium batteries. And why not? You can get perfectly-functional knockoffs on handy breakout boards from the usual online sources for pennies. Betteridge’s Law aside, [Lefty Maker] thinks that it may well be time to move on from the TP4056 and spends his latest video telling us why, along with promoting an alternative.

His part of choice is another TI chip, the BQ25185. [Lefty] put together his own charge controller board to show off the capabilities of this chip — including variable under- and over-charge protection voltages. Much of his beef with the TP4056 has less to do with that chip than with the cheap charge modules it comes on: when he crows about the lack of mounting holes and proper USB-PD on the knock-off modules, it occurs to us he could have had those features on his board even if he’d used a TP4056.

On the other hand, the flexibility offered by the BQ25185 is great to future-proof projects in case the dominant battery chemistry changes, or you just change your mind about what sort of battery you want to use. Sure, you’d need to swap a few resistors to set new trigger voltages and charging current, but that beats starting from scratch.

[Lefty Maker] also points out some of the advantages to making your own boards rather than relying on cheap modules. Namely, you can make them however you want. From a longer USB port to indicator LEDs and a built-in battery compartment, this charging board is exactly what [Lefty Maker] wants. Given how cheap custom PCBs are these days, it’s not hard to justify rolling your own.

The same cannot be said of genuine TI silicon, however. While the BQ25185 has a few good features that [Lefty Maker] points out in the video, we’re not sure the added price is worth it. Sure, it’s only a couple bucks, but that’s more than a 300% increase!

We’ve seen other projects pushing alternative charge controllers, but for now the TP4056 reigns as the easy option.

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Buying Large LiFePO4 Batteries: How Cheap Is Too Cheap?

August 7, 2025 by Maya Posch 43 Comments

It’s a well-known factoid that batteries keep getting cheaper while capacity increases. That said, as with any market that is full of people who are hunting for that ‘great deal’, there are also many shady sellers who will happily sell you a product that could be very dangerous. Especially in the case of large LiFePO₄ (LFP) batteries, considering the sheer amount of energy they can contain. Recently [Will Prowse] nabbed such a $125, 100 Ah battery off Amazon that carries no recognizable manufacturer or brand name.

If this battery works well, it could be an amazing deal for off-grid and solar-powered applications. Running a battery of tests on the battery, [Will] found that the unit’s BMS featured no over-current protection, happily surging to 400 A, with only over-temperature protection keeping it from melting down during a discharge scenario. Interestingly, under-temperature charge protection also worked on the unit.

After a (safe) teardown of the battery the real discoveries began, with a row of missing cells, the other cells being re-sleeved and thus likely salvaged or rejects. Fascinatingly, another YouTuber did a similar test and found that their (even cheaper) unit was of a much lower capacity (88.9 Ah) than [Will]’s with 98 Ah and featured a completely different BMS to boot. Their unit did however feature something of a brand name, though it’s much more likely that these are all just generic LFP batteries that get re-branded by resellers.

What this means is that these LFP batteries may be cheap, but they come with cells that are likely to be of questionable quality, featuring a BMS that plays it fast and loose with safety. Although [Will] doesn’t outright say that you shouldn’t use these batteries, he does recommend that you install a fuse on it to provide some semblance of over-current protection. Keeping a fire extinguisher at hand might also be a good idea.

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Save Cells From The Landfill, Get A Power Bank For Your Troubles

April 27, 2025 by Donald Papp 36 Comments

A hefty portable power bank is a handy thing to DIY, but one needs to get their hands on a number of matching lithium-ion cells to make it happen. [Chris Doel] points out an easy solution: salvage them from disposable vapes and build a solid 35-cell power bank. Single use devices? Not on his watch!

[Chris] has made it his mission to build useful things like power banks out of cells harvested from disposable vapes. He finds them — hundreds of them — on the ground or in bins (especially after events like music festivals) but has also found that vape shops are more than happy to hand them over if asked. Extracting usable cells is most of the work, and [Chris] has refined safely doing so into an art.

Disposable vapes are in all shapes and sizes, but cells inside are fairly similar.

Many different vapes use the same cell types on the inside, and once one has 35 identical cells in healthy condition it’s just a matter of using a compatible 3D-printed enclosure with two PCBs to connect the cells, and a pre-made board handles the power bank functionality, including recharging.

We’d like to highlight a few design features that strike us as interesting. One is the three little bendy “wings” that cradle each cell, ensuring cells are centered and held snugly even if they aren’t exactly the right size. Another is the use of spring terminals to avoid the need to solder to individual cells. The PCBs themselves also double as cell balancers, providing a way to passively balance all 35 cells and ensure they are at the same voltage level during initial construction. After the cells are confirmed to be balanced, a solder jumper near each terminal is closed to bypass that functionality for final assembly.

The result is a hefty power bank that can power just about anything, and maybe the best part is that it can be opened and individual cells swapped out as they reach the end of their useful life. With an estimated 260 million disposable vapes thrown in the trash every year in the UK alone, each one containing a rechargeable lithium-ion cell, there’s no shortage of cells for an enterprising hacker willing to put in a bit of work.

Power banks not your thing? [Chris] has also created a DIY e-bike battery using salvaged cells, and that’s a money saver right there.

Learn all about it in the video, embedded below. And if you find yourself curious about what exactly goes on in a lithium-ion battery, let our own Arya Voronova tell you all about it.

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