Solid-State Batteries Take To The Sky

June 17, 2026 by Bryan Cockfield 13 Comments

There always seem to be a handful of revolutionary technologies perpetually out of reach: fusion energy, quantum computers, and full self-driving cars are always in this list, and it seems like there’s also some battery technology which will finally let us fully decouple from fossil fuels in there as well. Although lithium batteries have allowed some ground-based electric transportation, the energy density is still not enough to enable full electrification, especially for things like aircraft. Solid state batteries may be on the verge of changing some of this, though, and a team has recently put them to work in a test aircraft to help make some headway with this novel battery chemistry.

The main contributing factor of these batteries’ improved energy densities is the ability to use a solid lithium anode, which has much higher energy density than the graphite-based anodes in modern liquid electrolyte batteries. Solid state batteries also have improved safety, since the solid electrolyte is generally not flammable and the battery itself is less prone to thermal runaway. The tests in this aircraft, a modified motorized glider, bear this out as well. With a standard lithium ion pack the team was able to harness 250 Wh/kg and with their new solid state battery they managed 410 Wh/kg, which let them fly the craft up to 24,000 feet (7,315 m) with the help of some wing-mounted solar panels.

Of course, a motorized glider is a long way away from battery-powered commercial flights, but tests like this are an important step on the way to de-carbonizing one of the more impactful industries on the planet, as well as hopefully making it less expensive to operate aircraft in the way EVs are generally much cheaper to operate than their internal combustion equivalents. But the limiting factor to adopting solid state batteries isn’t going to be implementation but rather the discovery of a cost effective way to manufacture them at scale. It’s the same reason we haven’t seen mass adoption of things like algae-based biodiesel or economic carbon capture yet.

Target The Best AA, And Take No Flak

November 9, 2025 by Tyler August 68 Comments

In this era of cheap lithium pouch cells, it might seem mildly anachronistic to build AA batteries into a project. There are enough valid reasons to do so, however, and enough legacy hardware that still takes AAs, that it’s worth spending some time deciding which batteries to use. Luckily for us, [Lumencraft] over on YouTube has done the legwork in the video embedded below, and even produced a handy-dandy spreadsheet.

Each battery in the test underwent three separate tests. There was the “leave it in a flashlight ’til it dies” test for real-world usage, but also discharge curves logged at 250mA and 2A. The curves for each are embedded in the spreadsheet so you can see what to expect, along with the calculated capacity at each discharge rate. 2A seems like a fairly brutal load for AAs, but it’s great to see how these cells react to extremes. The spreadsheet also includes the cell’s cost to create a value ranking, which will be of great use to our readers in the USA, where it appears [Lumencraft] is buying batteries. The world market is likely to have the same batteries available, but prices may vary by region, so it’s worth double-checking.

In the video, [Lumencraft] also takes the time to explain the four battery types commonly found in AA format, and the strengths and weaknesses of each chemistry that might cause you to prefer one over another for specific use cases, rather than going by his value rankings. Unsurprisingly, there’s virtually no reason other than cost to go for alkaline batteries in 2025. However, lithium-ion batteries in AA form don’t really outperform NiMH enough to make the added cost worthwhile in all applications, which is why the overall “best battery” is a “PowerOwl” NiMH. Li-ion’s unspectacular performance is likely in part due to the inefficiencies introduced by a built-in buck converter and safety circuitry. On the other hand, some people might really appreciate that extra safety compared to bare 18650 cells.

The results here aren’t too dissimilar to what we saw earlier this year, but we really appreciate [Lumencraft] publishing his results as a spreadsheet for easy reference. The only caveat is that he’s taking manufacturers at their word as to how many cycles the batteries will last.

Oh, and just to be 100% clear — we are talking about double-A batteries, not Anti-Aircraft batteries. If anyone has an anti-aircraft battery hack (especially if that hack includes double-A batteries powering the AA batteries), please send in a tip.

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Buyer Beware: Cheap Power Strips Hold Hidden Horrors

April 7, 2025 by Dan Maloney 84 Comments

We’ve got a love-hate relationship with discount tool outlet Harbor Freight: we hate that we love it so much. Apparently, [James Clough] is of much the same opinion, at least now that he’s looked into the quality of their outlet strips and found it somewhat wanting.

The outlet strips in question are Harbor Freight’s four-foot-long, twelve-outlet strips, three of which are visible from where this is being written. [James] has a bunch of them too, but when he noticed an intermittent ground connection while using an outlet tester, he channeled his inner [Big Clive] and tore one of the $20 strips to bits. The problem appears to be poor quality of the contacts within each outlet, which don’t have enough spring pre-load to maintain connection with the ground pin on the plug when it’s wiggled around. Actually, the contacts for the hot and neutral don’t look all that trustworthy either, and the wiring between the outlets is pretty sketchy too. The video below shows the horrors within.

What’s to be done about this state of affairs? That’s up to you, of course. We performed the same test on all our outlets and the ground connections all seemed solid. So maybe [James] just got a bad batch, but he’s still in the market for better-quality strips. That’s going to cost him, though, since similar strips with better outlets are about four times the price of the Harbor Freight units. We did find a similar strip at Home Depot for about twice the price of the HF units, but we can’t vouch for the quality. As always, caveat emptor.

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Testing At Scale

January 28, 2025 by Al Williams 15 Comments

We’ve said it before: building one-offs is different from building at scale. Even on a small scale. There was a time when it was rare for a hobbyist to produce more than one of anything, but these days, access to cheap PC boards makes small production runs much more common. [VoltLog], for example, is selling some modules and found he was spending a lot of time testing the boards. The answer? A testing jig for his PC board.

Big factories, of course, have special machines for bulk testing. These are usually expensive. [VoltLog] found a place specializing in creating custom test jigs using 3D printing.

They also have some standard machines. He did have to modify his PCB to accommodate special test points. He sent the design files to the company, and they produced a semi-custom testing jig for the boards in about a month.

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Laser-Cut Metal Endoskeleton Beefs Up 3D Prints

January 24, 2025 by Dan Maloney 24 Comments

There are limits to what you can do with an FDM printer to make your parts stronger. It really comes down to adding more plastic, like increasing wall thickness or boosting up the infill percentage. Other than that, redesigning the part to put more material where the part is most likely to fail is about the only other thing you can do. Unless, of course, you have access to a fiber laser cutter that can make internal metal supports for your prints.

As [Paul] explains it, this project stemmed from an unfortunate episode where a printed monitor stand failed, sending the LCD panel to its doom. He had taken care to reinforce that part by filling it with fiberglass resin, but to no avail. Unwilling to risk a repeat with a new tablet holder, he decided to test several alternative methods for reinforcing parts. Using a 100 W fiber laser cutter, he cut different internal supports from 0.2 mm steel shim stock. In one case he simply sandwiched the support between two half-thickness brackets, while in another he embedded the steel right into the print. He also made two parts that were filled with epoxy resin, one with a steel support embedded and one without.

The test setup was very simple, just a crane scale to measure the force exerted by pulling down on the part with his foot; crude, but effective. Every reinforced part performed better than a plain printed part with no reinforcement, but the clear winner was the epoxy-filled part with a solid-metal insert. Honestly, we were surprised at how much benefit such a thin piece of metal offered, even when it was directly embedded into the print during a pause.

Not everyone has access to a fiber laser cutter, of course, so this method might not be for everyone. In that case, you might want to check out other ways to beef up your prints, including just splitting them in two.

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AA Battery Performances Tested, So Get The Most For Your Money

January 10, 2025 by Donald Papp 39 Comments

[Project Farm] has a video in which a wide variety of AA cells are analyzed and compared in terms of capacity, internal resistance, ability to deliver voltage under load, and ability to perform in sub-freezing temperatures. Alkaline, lithium, and even some mature rechargeable cells with a couple thousand cycles under their belt were all compared. There are a few interesting results that will can help you get the most from your money the next time you’re battery shopping.

The video embedded below demonstrates a set of tests that we recommend you check out, but the short version is that more expensive (non-rechargeable) lithium cells outperform their alkaline peers, especially when it comes to overall longevity, ability to perform under high-drain conditions, and low temperatures. Lithium cells also cost more, but they’re the right choice for some applications.

Some brands performed better and others worse, but outside of a couple stinkers most were more or less comparable. Price however, was not.

As for how different brands stack up against one another, many of them are more or less in the same ballpark when it comes to performance. Certainly there are better and worse performers, but outside of a couple of stinkers the rest measure up reasonably well. Another interesting finding was that among rechargeable cells that were all several years (and roughly 2,200 charge-discharge cycles) old, a good number of them still performed like new.

Probably the single most striking difference among the different cells is cost — and we’re not just talking about whether lithium versus alkaline AAs are more cost-effective in the long run. Some brands simply cost twice as much (or more!) than others with comparable performance. If you’re in a hurry, jump to [Project Farm] presenting the final ranked results at 19:45 in.

Relying on brand recognition may save you from buying complete junk, but it’s clearly not the most cost-effective way to go about buying batteries. These findings are similar to an earlier effort at wide-scale battery testing which also determined that factoring in price-per-cell was too significant to ignore.

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Making Sure Your Patch Cables Are Ready For RF Work

January 8, 2025 by Dan Maloney 3 Comments

How do you know that your patch cables are good? For simple jumper wires, a multimeter is about all you need to know for sure. But things can get weird in the RF world, in which case you might want to keep these coaxial patch cable testing tips in mind.

Of course, no matter how high the frequency, the basics still apply, and [FesZ] points out in the video below that you can still get a lot of mileage out of the Mark 1 eyeball and a simple DMM. Visual inspection of the cable and terminations can reveal a lot, as can continuity measurements on both the inner and outer conductors. Checking for shorts between conductors is important, too. But just because the cable reads good at DC doesn’t mean that problems aren’t still lurking. That’s when [FesZ] recommends breaking out a vector network analyzer like the NanoVNA. This tool will allow you to measure the cable’s attenuation and return loss parameters across the frequency range over which the cable will be used.

For stubborn problems, or just for funsies, there’s also time-domain reflectometry, which can be done with a pulse generator and an oscilloscope to characterize impedance discontinuities in the cable. We’ve covered simple TDR measurement techniques before, but [FesZ] showed a neat trick called time-domain transformation, which uses VNA data to visualize the impedance profile of the whole cable assembly, including its terminations.

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