Lithium-Ion Batteries: WHY They Demand Respect

November 4, 2025 by Arya Voronova 59 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” →

The WHY 2025 Badge And Its 18650s

August 12, 2025 by Jenny List 38 Comments

The largest European hacker camp this year was in the Netherlands — What Hackers Yearn (WHY) 2025 is the latest in the long-running series of four-yearly events from that country, and 2025 saw a move from the Flevoland site used by SHA2017 and MCH2021, back to just north of Alkmaar in Noord-Holland, where the OHM2013 event took place. WHY has found itself making the news in the Dutch technical media for all the wrong reasons over the last few days, after serious concerns were raised about the fire safety of its badge.

The cell supplied with a WHY 2025 badge, with very clear fire safety warning — This is the cell supplied with the WHY badge, complete with manufacturer’s warning.

The concerns were raised from the RevSpace hackerspace in Leidschendam, and centre around the design of the battery power traces on the PCB between the battery holders and the power supply circuitry. Because the 18650 cells supplied with that badge lack any protection circuitry, bridging the power traces could be a fire risk.

In short: their report names the cell holders as having tags too large for their pads on the PCB, a too-tight gap between positive and negative battery traces, protected only by soldermask, and the inadequacy of the badge’s short circuit protection. In the event that metal shorted these battery tags, or wore through the soldermask, the batteries would be effectively shorted, and traces or components could get dangerously hot.

The WHY organizers have responded with a printed disclaimer leaflet warning against misuse of the cells, and added a last-minute epoxy coating to the boards to offer additional protection. Some people are 3D-printing cases, which should also help reduce the risk of short-circuiting due to foreign metal objects. Using an external powerbank with short-circuit protection instead of the cells would solve the problem as well. Meanwhile a group of hackers collecting aid for Ukraine are accepting the batteries as donations.

It’s understood that sometimes bugs find their way into any project, and in that an event badge is no exception. In this particular case, the original Dutch badge team resigned en masse at the start of the year following a disagreement with the WHY2025 organizers, so this badge has been a particularly hurried production. Either way, we are fortunate that the issue was spotted, and conference organizers took action before any regrettable incidents occurred.