Feature: Batteries


Ensuring compliance without compromising performance or cost efficiency requires a deep understanding of both technical and regulatory landscapes. Custom battery pack manufacturers with expertise in international standards and shipping regulations can help OEMs streamline certification, avoiding costly delays and develop and ensuring a market-ready battery solution. An experienced battery partner builds compliance into the design process early, helping OEMs avoid costly redesigns, certification delays and supply chain disruptions.


Innovations shaping the future of power tool batteries While cylindrical cells continue to dominate, emerging battery technologies could bring significant advancements in performance, safety and efficiency for power tools. One of the most promising developments is AI-powered battery management systems (BMS), which enable batteries to monitor their own health, optimise power delivery based on usage patterns and regulate temperature in real time. Tis technology enhances both battery lifespan and tool performance, ensuring more consistent power output even in demanding environments. Another innovation gaining traction is the tables cell design,


which aims to reduce internal resistance and heat generation. Unlike traditional cylindrical cells, where tabs limit current flow, this design allows for faster charging and discharging, improved efficiency, and better thermal management. While still in its early stages, the technology has the potential to improve power tool performance and battery longevity if manufacturers can scale production cost-effectively. Silicon anode batteries are also drawing attention, offering higher


energy density, longer runtimes and faster charging. Historically, these batteries have faced challenges with swelling, sometimes expanding up to three times their original size. However, recent design improvements claim to have mitigated this issue, making them a potential game- changer for power tools if they prove stable in real-world applications.


Looking further ahead, solid-state batteries could introduce


even greater safety and efficiency by replacing traditional liquid electrolytes with a solid material. This change could reduce the risk of thermal runaway while also increasing energy density and cycle life. However, solid-state technology remains expensive and is not yet widely scalable for power tools. If manufacturers can overcome these hurdles, it could become one of the most significant advancements in battery technology in the coming years.


The advantage of a knowledgeable battery partner Innovation is key to staying competitive in the power tool market, and battery technology is evolving fast. Advances in AI-powered BMS, high-energy-density chemistries and new cell designs bring opportunities to improve performance, safety, and user experience. But integrating these advancements into a reliable, manufacturable solution isn’t always straightforward. Standardised, off-the-shelf battery options can only go so far, and for many OEMs, they no longer provide the performance, durability or flexibility needed for demanding applications. A strong battery partner helps OEMs make the right


choices at every stage, from defining mechanical and electrical specifications to ensuring regulatory compliance and managing logistical considerations. Te right expertise ensures that battery packs are safe, durable and optimised for real-world conditions, while also helping to avoid costly delays or design limitations that could impact product success. Beyond technical expertise, an experienced partner offers


valuable insight into emerging technologies and market trends, helping OEMs future-proof their designs and stay ahead of shiſting regulations. With battery technology playing an ever- greater role in product differentiation, working with a specialist ensures power tool manufacturers can deliver high-performance, regulation-ready products with confidence.


www.electronicsworld.co.uk April 2025 29


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