Home > Batteries > Disruptive Innovation in the Battery Industry: Lithium-ion vs LIPO

Disruptive Innovation in the Battery Industry: Lithium-ion vs LIPO

Jun. 23, 2025

Disruptive Innovation in the Battery Industry: Lithium-ion vs LIPO

Today, Ford is considered the victim of disruptive innovation as its competition came from a new type of car company called Tesla. Ford thought their #1 competitor was General Motors." However it turns out they were wrong about this as their real rivalry came from a Silicon Valley startup, focused on electric vehicles and software rather than pickup trucks and horsepower. Today, Tesla’s market cap is roughly six times the combined market cap of GM and Ford.

Click here to get more.

Kodak made the same mistake, thinking its competition was Fuji Film. Its greatest threat came from the digital camera. Today, my children have no idea what a "Kodak Moment" is.

This is disruptive innovation.

Clay Christensen of Harvard Business School famously defined Disruptive Innovation as “the process by which a smaller company—usually with fewer resources—moves upmarket and challenges larger, established businesses.”

In technology, this happens when something new comes along and changes the way things are done. The old technology needs to find a new niche market to avoid becoming obsolete overnight.

Have lithium polymer (LIPO) batteries disrupted the lithium-ion ( and ) industry?

The battery industry has seen disruptive innovation over recent years, with lithium-ion products giving way to lithium polymer (LIPO) technology. Polymers are smaller and easier to manufacture in various sizes, but they're also more difficult to mass produce at scale. LIPO’s lack of manufacturing quality and consistency can create major problems. To appreciate the challenges of manufacturing safe LIPO batteries, consider Samsung’s Galaxy S7’s LIPO polymer catching fire and estimated $5.3B recall! Despite these challenges, the benefits of LIPO’s disruptive innovation can be seen in many consumer devices.

Before LIPO technology was developed, lithium-ion batteries were standard in consumer electronics. Consider the replaceable battery in your old laptop, which was battery pack composed of four 3.7V lithium-ion batteries connected in series (a 4S1P battery). Advanced lithium-ion batteries were available with extra cells in parallel (a 4S2P battery) to extend their lifespan. The battery pack was a safe, accessible, and a high-quality energy storage solution. Individual battery cells usually came from a high-quality manufacturer like Panasonic, LG, Moli or Samsung; and in most cases, they contained a CID (current interrupter device). Today, however, high-end “ultra thin” laptops like the Lenovo X1 Carbon or Apple MacBook are all powered by LIPO batteries.

Lithium polymer batteries were originally intended for single cell (3.7V) applications, as their quality was insufficient to combine cells in series. Furthermore, cells frequently expanded due to natural "puffing", which would crack cases and led to poor public perception during the early days. These batteries have improved dramatically over recent years, thanks to numerous technological advances. New battery designs have allowed for decreased dimensions, higher quality, and extra capacity.

Due to their thin foil construction, LIPO batteries don't require the same metal casing as batteries. Instead, they're die cut from a "multi-layer cake" of cathode, anode, and separator. This provides great flexibility, as their capacity can be increased by adding layers to the cake or expanding the overall dimensions. This also allows for the polymer to be cut in various unique shapes, such as the circles required for smartwatch products.

LIPO v lithium-ion — which technology is the winner?

From lightweight laptops to tablets and smartphones, modern technology predominantly uses lithium polymer technology. Said differently, LIPO has disrupted the "low voltage-low capacity-low power" end of the battery industry spectrum. Due to its robust nature, however, lithium-ion and lithium-ion phosphate technology remains dominant for high voltage, high capacity, and high power applications. For example, modern electric cars and bikes use lithium-ion and lithium iron phosphate batteries rather than LIPO technology.

LIPO poses major challenges for industrial applications

The first challenge is related to manufacturing quality, as low-cost, low-quality "tier two" and "tier three" suppliers abound. The industry is driven by low-cost consumer toys like $15 children's drones and talking dolls. For these applications, price is more important than product quality or consistency of production. In these cases, a high percentage of cells fail to meet their rated capacity and calendar life because they experience puffing in the field.

The second problem is related to performance. The high-variation in performance among polymer cells makes them difficult to use in battery packs, both in series and in parallel. When cell performance remains inconsistent over many cycles, a range of problems is likely to occur.

LIPO v lithium-ion batteries for industrial applications

Engineers should consider these guidelines when deciding between LIPOs and lithium-ion batteries for industrial applications:

1. Use industrial-grade LIPOs - You should avoid consumer-grade polymers to save yourself from field failures and endless frustration. Along with failure, consumer-grade cells often reach end-of-life quickly (are discontinued) when manufacturers modify cells for new consumer products. An example of a high-quality LIPO manufacturer is Kokam https://kokam.com/en/. Rose has built battery packs with their cells for exoskeleton applications.

2. Go up to 2S1P - You should use polymers in 1s1p and 2s1p configurations whenever feasible. Use them in series rather than parallel and avoid going above 2s. This helps to minimize the impacts of cell variation.

3. Use matching date codes - All of the modules you use should contain identical matched cells (same date codes) throughout the assembly. Consistency between cells helps to create uniformity in performance.

4. Use LIPOs for energy applications - While standard polymers may be used to power digital electronics, you should generally avoid using them to power mechanical applications such as motors. Instead, you should utilize them in low-load situations. High-current loads cause greater variation in cell performance and faster deterioration over time. If you do use a LIPO for a high-power application, make sure to use a cell designed for high-power.

5. Use for power applications - For high-load applications, use lithium-ion or cells rather than LIPO products. While the weight and size will increase, the overall quality, safety, and performance will be considerably superior. You can observe this in the drone business, with cheaper products making use of LIPO and delivery services utilizing lithium-ion cells.

Example from the Drone and Robotics Industry

The drones and robotics industry is a perfect illustration of how LIPO batteries work in contrast to lithium-ion. For instance, low power (lightweight) consumer grade models like DJI MAVIC PRO are powered by LIPOs while industrial grade drones such as Zipline’s use cells for their battery pack (at least according this CNET publication)

Conclusion

Lithium polymer batteries may have disrupted the low-voltage end of the battery industry, but they still pose challenges for industrial users. These challenges include inferior manufacturing quality and high performance variation between cells. When using polymers for industrial applications, engineers should avoid consumer-grade polymers, choose 1s1p and 2s1p configurations whenever possible, and use lithium-ion cells rather than LIPO for high-load applications. If you want to avoid problems and purchase the right batteries, Rose offers a comprehensive selection of industrial-grade lithium polymer (LIPO) cells.

At Rose, we offer an extensive selection of high-quality lithium polymer batteries for industrial applications. Our experts will help you to select batteries and design a custom battery pack that meets your specific needs. Please contact our support team to learn more.

How to Choose Reliable Li Polymer Battery Manufacturers for Your ...

How to Choose Reliable Li Polymer Battery Manufacturers for Your Business

In a world increasingly powered by portable electronics, the selection of dependable Li Polymer battery manufacturers is a critical decision that can significantly impact a business’s product quality, supply chain stability, and overall reputation. For companies in sectors ranging from consumer electronics and medical devices to industrial applications and beyond, the right battery partner ensures not only the performance and safety of their products but also their long-term market success. This comprehensive guide provides a detailed roadmap for navigating the complexities of the Li-Polymer battery industry and forging a successful partnership with a reliable manufacturer.

The Power of the Right Partnership: Why Your Battery Manufacturer Matters

The global Li-Ion battery market, of which Li-Polymer is a significant segment, is projected to reach $135.1 billion by , growing at a CAGR of 13.1% from to . This rapid growth underscores the increasing demand for high-quality, reliable power sources. Choosing the right manufacturer is not merely a procurement decision; it’s a strategic one that can yield substantial dividends.

Key Points:

Further reading:
Marine battery vs Car battery: Pros & Cons

Product Performance and Safety: A reputable manufacturer adheres to stringent quality control measures, ensuring their batteries deliver consistent performance and meet international safety standards, mitigating the risk of product failures, recalls, and potential harm to end-users.
Supply Chain Resilience: A reliable partner guarantees a stable and timely supply of batteries, preventing costly production delays and ensuring your products reach the market as planned.
Brand Reputation: High-quality components, including the battery, contribute to a positive user experience, enhancing your brand’s reputation for quality and reliability. Conversely, a faulty battery can lead to negative reviews and damage brand equity.
Cost-Effectiveness in the Long Run: While upfront costs are a consideration, a dependable manufacturer can reduce long-term expenses associated with warranty claims, product replacements, and the reputational damage of a product failure.

A Detailed 8-Step to Choose Reliable Li Polymer Battery Manufacturers

How to Find the Best Home EV Charger - Consumer Reports

A meticulous evaluation process is the cornerstone of selecting a reliable Li-Polymer battery manufacturer. This eight-step approach provides a structured framework for your assessment.

Step 1: Deep Dive into Company Experience and Reputation

A manufacturer’s history and standing in the industry are strong indicators of their reliability.

If you are looking for more details, kindly visit JOINSUN.

Key Points to Cover:
- Years in Business: A longer operational history often signifies stability and a deeper understanding of the market.
- Industry Focus: Do they specialize in batteries for your specific industry (e.g., medical, consumer electronics, automotive)? This can translate to a better understanding of your unique requirements.
- Customer Reviews and Testimonials: Look for feedback on independent platforms and industry forums.
- Case Studies and Client Portfolio: A strong portfolio with recognizable clients demonstrates a track record of success.

Step 2: Scrutinizing Quality Management Systems and Certifications

Certifications are not just a formality; they are a testament to a manufacturer’s commitment to quality and safety.

Key Points to Cover:
- ISO : This is the international standard for a quality management system (QMS). It ensures the manufacturer has documented processes and a commitment to continuous improvement.
- ISO : This certification indicates a commitment to environmental management standards.
- Product-Specific Safety Certifications:
  - UL & UL : Crucial for products sold in North America, these standards cover the safety of lithium batteries and battery packs.
  - IEC : The international safety standard for rechargeable batteries.
  - UN 38.3: Mandatory for the transportation of lithium batteries, ensuring they can withstand the rigors of shipping.
- Material and Substance Compliance: RoHS (Restriction of Hazardous Substances) and REACH (Registration, Evaluation, Authorisation and Restriction of Chemicals) are essential for products sold in the European Union.

Step 3: Assessing Technical Capabilities and R&D

The manufacturer’s technical prowess will directly impact the performance and innovation of your product.

Key Points to Cover:
- In-house R&D Team: A dedicated research and development team indicates a commitment to staying at the forefront of battery technology.
- Customization Capabilities: Can they tailor battery size, shape, capacity, and BMS to your specific needs? This is a hallmark of a sophisticated manufacturer.
- Prototyping and Testing Facilities: In-house testing capabilities for performance, safety, and cycle life are crucial for ensuring the battery meets your specifications.
- Understanding of Your Application: A good manufacturer will ask detailed questions about your product to recommend the optimal battery solution.

Step 4: Evaluating Production Capacity and Scalability

The manufacturer must be able to meet your current and future production demands.

Key Points to Cover:
- Production Line and Automation: A modern, automated production line can lead to greater consistency and higher output.
- Minimum Order Quantity (MOQ): Ensure their MOQ aligns with your business needs.
- Lead Times: Understand their typical lead times for both standard and custom orders.
- Scalability: Can they ramp up production as your business grows?

Step 5: Communication, Transparency, and Support

Clear and consistent communication is vital for a successful long-term partnership.

Key Points to Cover:
- Responsiveness: How quickly do they respond to your inquiries?
- English Proficiency: For international partnerships, ensure their team has a strong command of English to avoid miscommunication.
- Dedicated Point of Contact: Having a dedicated account manager can streamline communication.
- Transparency in Processes: Are they willing to share information about their production process and quality control measures?

Step 6: Conducting a Factory Audit

If feasible, a physical or virtual factory audit is invaluable.

Key Points to Cover:
- Cleanliness and Organization: A well-organized facility is often indicative of a well-run operation.
- Adherence to Safety Protocols: Observe if workers are following safety procedures.
- Quality Control Checkpoints: Identify the various stages of quality control throughout the manufacturing process.
- Employee Morale and Working Conditions: A positive work environment can contribute to better product quality.

Step 7: Analyzing Cost and Value

While cost is important, it should be evaluated in the context of overall value.

Key Points to Cover:
- Detailed Quotations: Request a breakdown of costs, including tooling, samples, and mass production.
- Total Cost of Ownership: Consider factors beyond the per-unit price, such as warranty, support, and the potential costs of poor quality.
- Negotiation: Be prepared to negotiate on price, but not at the expense of quality.

Step 8: Reviewing Warranty and After-Sales Support

A strong warranty and reliable after-sales support provide a safety net.

Key Points to Cover:
- Warranty Period and Terms: Understand what is covered and for how long.
- Process for Handling Defective Products: A clear and efficient process for returns and replacements is essential.
- Technical Support Availability: Ensure they have technical support available to assist with any issues that may arise.

Building a Lasting Partnership: Beyond the Initial Selection

Once you’ve selected a manufacturer, the work doesn’t stop. Building a strong, collaborative relationship is key to long-term success.

Key Points:
- Clear and Detailed Contracts: Ensure all terms, including specifications, quality standards, delivery schedules, and payment terms, are clearly outlined in a legally binding contract.
- Regular Communication: Maintain open lines of communication to address any potential issues proactively.
- Collaborative Product Development: Involve your manufacturer in the early stages of product development to leverage their expertise.

Frequently Asked Questions (FAQ) about Choosing Li-Polymer Battery Manufacturers

What are the most important certifications to look for in a Li-Polymer battery manufacturer?
- At a minimum, look for ISO for quality management, UL / for safety (especially for the North American market), IEC for international safety compliance, and UN 38.3 for transportation.
How can I verify a manufacturer’s claims about their production capacity?
- Request a factory tour (virtual or in-person), ask for production data from similar projects, and inquire about their equipment and level of automation.
What is a reasonable lead time for custom Li-Polymer battery packs?
- Lead times can vary significantly based on the complexity of the design, material availability, and the manufacturer’s production schedule. Generally, expect anywhere from 4 to 12 weeks for custom orders.
How much should I expect to pay for custom Li-Polymer batteries?
- Pricing is highly dependent on factors such as capacity, size, chemistry, the complexity of the BMS, and order quantity. It’s best to get detailed quotes from multiple manufacturers.
What are the biggest red flags to watch out for when evaluating a potential manufacturer?
- Lack of transparency, an unwillingness to provide certifications, poor communication, an outdated or disorganized factory, and unusually low pricing can all be red flags.
Is it better to work with a domestic or an overseas manufacturer?
- Both have their pros and cons. Domestic manufacturers may offer easier communication and faster shipping, while overseas manufacturers, particularly in Asia, often provide more competitive pricing. The best choice depends on your specific priorities.
What is a Battery Management System (BMS) and why is it important?
- A BMS is an electronic system that manages a rechargeable battery. It is crucial for safety and longevity, as it protects against overcharging, over-discharging, over-current, and short circuits. A high-quality BMS is a key component of a reliable battery pack.

Conclusion: Powering Your Business’s Future

The process of selecting a reliable Li-Polymer battery manufacturer is a significant undertaking, but it is an investment that will pay dividends in the form of a high-quality, safe, and successful product. By conducting thorough due diligence, asking the right questions, and prioritizing long-term value over short-term cost savings, you can forge a powerful partnership that will help your business thrive in an increasingly electrified world.

If you’re looking for a trusted manufacturer that offers custom LiPo battery solutions, robust R&D capabilities, and a proven track record across industries like wearables, IoT, drones, and medical devices — Lan Dazzle is here to power your innovation.

Marine battery vs Car battery: Pros & Cons

Complete Guide for purchasing batteries for your RV

Comments

Guest Posts

If you are interested in sending in a Guest Blogger Submission,welcome to write for us!

Your Name: (required)

Your Email: (required)

Subject:

Your Message: (required)