Curved batteries unlock 10-30% extra volume in wearable enclosures, but they also introduce manufacturing trade-offs that affect cycle life. This article explains what to ask your battery vendor before committing to a curved design.
Minimum curvature radius
For single-curvature cells we recommend R ≥ 25 mm to maintain coating integrity over 500 cycles. Tighter radii are achievable but require thinner electrodes and reduce capacity.