Engineers have developed a new type of wearable battery that’s more flexible, stretchable, and breathable, thanks to a unique hole pattern.
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A team of engineers and materials scientists from the U.S. has pioneered a new design for wearable batteries that are significantly more flexible and breathable than traditional models. Their research shows how strategically placed holes of specific sizes and shapes allow a standard battery pouch to bend and stretch like never before.
As electronics continue to shrink and become more resilient, researchers have focused on incorporating them, particularly batteries, into wearable clothing. While some tiny devices only require minimal power that can be provided through movement, most others need a more robust power source. However, integrating batteries into clothing presents challenges related to size, weight, stiffness, and safety concerns such as overheating or fires.
The design addresses these issues by introducing a new approach to battery pouch flexibility. Typically, battery pouches are somewhat flexible but not enough for seamless integration into clothing. While previous studies explored adding square or round holes in pouches to increase flexibility, this new research delves deeper into the ideal placement and dimensions of the holes.
The result is a battery featuring rectangular holes, both long and short, placed at key locations to maximize stretchability without sacrificing capacity. When tested, the battery maintained its charge even when folded 180 degrees and could stretch up to 10% of its original length. Remarkably, it survived over 100 folding cycles without any degradation. Furthermore, the holes not only enhanced flexibility but also improved breathability, making the battery twice as breathable as cotton, and helped dissipate heat, preventing overheating. This design could bring us one step closer to seamlessly integrating energy sources into smart clothing, opening the door to more comfortable and efficient wearables.
References: Lin Xu et al., “Stretchable, breathable, wearable batteries using a holey design,” Matter (2025), DOI: 10.1016/j.matt.2025.101959