battery

414 Articles

There’s Always Room For 3D Printed Batteries

February 14, 2026 by 17 Comments

There are many applications where you have limits on how much you can cram into a particular space. There are also many applications where you need as much battery as you can get. At the intersection of those applications, you may soon be able to 3D print custom batteries to fit into oddly shaped spaces that might otherwise go to waste.

Commercial batteries are typically cylindrical or rectangular. In theory, you could build tooling to make batteries of any size or shape you want, but it’s an expensive process in small quantities. [Lawrence Ulrich] on Spectrum talks about a new process, developed by [Gabe Elias], that can print anodes, cathodes, separators, and casings for custom battery shapes with no costly tooling.

As an example, consider an unmanned aerial vehicle crammed with avionics. You could put off-the-shelf batteries in the wings, but you’ll end up wasting a lot of space. A custom battery could fill the wing’s interior completely. The post also mentions batteries shaped like the earpieces of a pair of smart glasses.

A prototype showed that in the space of 48 cylindrical cells, the new process could deliver a printed battery that uses 35% more of the available volume and a 50% boost in energy density.

Could you do this yourself? Maybe, but it won’t be trivial. The current process requires a liquid electrolyte and the ability to produce thin layers of exotic materials. What oddly-shaped battery would you like to see? Us? We’d like to have a battery for a laptop that was spread uniformly so there wasn’t a heavy side that has the battery.

A Working Intercom From Antique Telephones

February 9, 2026 by 13 Comments

Although it can be hard to imagine in today’s semiconductor-powered, digital world, there was electrical technology around before the widespread adoption of the transistor in the latter half of the 1900s that could do more than provide lighting. People figured out clever ways to send information around analog systems, whether that was a telegraph or a telephone. These systems are almost completely obsolete these days thanks to digital technology, leaving a large number of rotary phones and other communications systems relegated to the dustbin of history. [Attoparsec] brought a few of these old machines back to life anyway, setting up a local intercom system with technology faithful to this pre-digital era.

These phones date well before the rotary phone that some of us may be familiar with, to a time where landline phones had batteries installed in them to provide current to the analog voice circuit. A transformer isolated the DC out of the line and amplified the voice signal. A generator was included in parallel which, when operated by hand, could ring the other phones on the line. The challenge to this build was keeping everything period-appropriate, with a few compromises made for the batteries which are D-cell batteries with a recreation case. [Attoparsec] even found cloth wiring meant for guitars to keep the insides looking like they’re still 100 years old. Beyond that, a few plastic parts needed to be fabricated to make sure the circuit was working properly, but for a relatively simple machine the repairs were relatively straightforward.

The other key to getting an intercom set up in a house is exterior to the phones themselves. There needs to be some sort of wiring connecting the phones, and [Attoparsec] had a number of existing phone wiring options already available in his house. He only needed to run a few extra wires to get the phones located in his preferred spots. After everything is hooked up, the phones work just as they would have when they were new, although their actual utility is limited by the availability of things like smartphones. But, if you have enough of these antiques, you can always build your own analog phone network from the ground up to support them all.

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Pendulum Powered Battery

February 8, 2026 by 23 Comments

While the average person would use a standard charger to top off their phone, [Tom Stanton] is no average man. Instead, he put mind to matter with an entire pendulum battery system.

Using the inductive effects of magnets on copper coils, [Tom] found the ability to power small components. With that in mind, the only path was forward with a much larger pendulum. A simple diode rectifier and capacitors allow for a smoother voltage output. The scale of the device is still too small to power anything insane, even the phone charging test is difficult. One thing the device can do is juice up the electromagnetic launcher he put together a couple years back to hurl an RC plane into the air.

The useful applications of pendulum power storage might not be found in nationwide infrastructure, but the application on this scale is certainly a fun demonstration. [Tom] has a particular fascination with similar projects where practical application comes second to novelty. For a perfect example of this, check out his work with air powered planes!

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Investigating The Science Claims Behind The Donut Solid State Battery

February 8, 2026 by 63 Comments

Earlier this year Donut Lab caused quite the furore when they unveiled what they claimed was the world’s first production-ready solid state battery, featuring some pretty stellar specifications. Since then many experts and enthusiasts in the battery space have raised concerns that this claimed battery may not be real, or even possible at all. After seeing the battery demonstrated at CES’26 and having his own concerns, [Ziroth] decided to do some investigating on what part of the stated claims actually hold up when subjected to known science.

On paper, the Donut Lab battery sounds amazing: full charge in less than 10 minutes, 400 Wh/kg energy density, 100,000 charge cycles, extremely safe and low cost. Basically it ticks every single box on a battery wish list, yet the problem is that this is all based on Donut’s own claims. Even aside from the concerns also raised in the video about the company itself, pinning down what internal chemistry and configuration would enable this feature set proves to be basically impossible.

In this summary of research done on Donut’s claimed battery as well as current battery research, a number of options were considered, including carbon nanotube-based super capacitors. Yet although this features 418 Wh/kg capacity, this pertains only to the basic material, not the entire battery which would hit something closer to 50 Wh/kg.

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Comprehensive Power Management For The Raspberry Pi

January 30, 2026 by 6 Comments

The Raspberry Pi has been a revolutionary computer in the maker space, providing a full Linux environment, GUI, and tons of GPIO and other interfacing protocols at a considerably low price. This wasn’t its original intended goal, though. Back in the early 2010s it was supposed to be an educational tool for students first, not necessarily a go-to for every electronics project imaginable. As such there are a few issues with the platform when being used this way, and [Vin] addresses his problems with its power management in his latest project.

[Vin]’s main issue is that, unlike a microcontroller, the Raspberry Pi doesn’t have a deep sleep function. That means that even when the operating system is shut down the computer is still drawing an appreciable amount of current, which will quickly drain some batteries. We’ve covered [Vin]’s farm and his use case for the Raspberry Pi in the past, but a quick summary is that these boards are being used in a very rugged environment where utility power isn’t as reliable as he would like.

In [Vin]’s post he not only outlines his design for the board but goes through his design process, starting by using discrete logic components and then trying out various microcontrollers until settling on an ATmega88. The microcontroller communicates with the Raspberry Pi over I2C where the Pi can request a power-down as well as a time for future power-on. A latching relay controlled by the microcontroller ensures the Pi doesn’t drain any battery while the ATmega can put itself into actual sleep in the meantime.

The build for this project goes into an impressive amount of detail, and not only are the designs and code available on the project’s GitHub page but [Vin] also wrote another blog post which uses this project to go over his design philosophy more broadly.

Lead Acid Battery Upgraded To Lithium Iron Phosphate

January 23, 2026 by 15 Comments

Lithium batteries have taken over as the primary battery chemistry from applications ranging from consumer electronics to electric vehicles and all kinds of other things in between. But the standard lithium ion battery has a few downsides, namely issues operating at temperature extremes. Lead acid solves some of these problems but has much lower energy density, and if you want to split the difference with your own battery you’ll need to build your own lithium iron phosphate (LiFePO4) pack.

[Well Done Tips] is building this specific type of battery because the lead acid battery in his electric ATV is on the decline. He’s using cylindrical cells that resemble an 18650 battery but are much larger. Beyond the size, though, many of the design principles from building 18650 battery packs are similar, with the exception that these have screw terminals so that bus bars can be easily attached and don’t require spot welding.

With the pack assembled using 3D printed parts, a battery management system is installed with the balance wires cleverly routed through the prints and attached to the bus bars. The only problem [Well Done Tips] had was not realizing that LiFePO4 batteries’ voltages settle a bit after being fully charged, which meant that he didn’t properly calculate the final voltage of his pack and had to add a cell, bringing his original 15S1P battery up to 16S1P and the correct 54V at full charge.

LiFePO4 has a few other upsides compared to lithium ion as well, including that it delivers almost full power until it’s at about 20% charge. It’s not quite as energy dense but compared to the lead-acid battery he was using is a huge improvement, and is one of the reasons we’ve seen them taking over various other EV conversions as well.

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Old Windsurfers Become New Electric Surfboards

January 13, 2026 by 11 Comments

Windsurfing has experienced a major decline in popularity in the last few decades as the sport’s culture failed to cater to beginners at the same time that experienced riders largely shifted to kiteboarding. While it’s sad to see a once-popular and enjoyable sport lose its mass market appeal, it does present a unique opportunity for others as there’s cheap windsurfing gear all over the online classifieds now. [Dane] recently found that some of these old boards are uniquely suited to be modified into electric surfboards.

The key design element of certain windsurfers that makes this possible is the centerboard, a fin mounted on the windsurfer extending down into the water that resists the lateral force of the sail, keeping the board moving forward instead of sideways. [Dane] used this strengthened area of the board to mount a submerged electric motor, with all of the control electronics and a battery on the top of the board. The motor controller did need a way to expel excess heat while being in a sealed waterproof enclosure, but with a hole cut in the case and a heat sink installed on top of it, this was a problem quickly solved.

The operator control consists of a few buttons which correspond to pre-selected speeds on the motor. There’s no separate control input for steering, though; in order to turn this contraption the operator has to lean the board. With some practice it’s possible to stand up on this like any other electric surfboard and scoot around [Dane]’s local lake. For the extreme budget version of this project be sure to check out [Ben Gravy]’s model which involves duct taping two cheap surfboards together instead.