Comment by ianferrel

Comment by ianferrel 2 days ago

103 replies

>the solution came with rearranging and adjusting the cells to ensure the packs worked more efficiently.

>Glubux even began disassembling entire laptop batteries, removing individual cells and organizing them into custom racks. This task, which likely required a great deal of manual labor and technical knowledge, was key to making the system work effectively and sustainably.

This kind of thing is cool as a passion project, but it really just highlights how efficient the modern supply chain is. If you have the skills of a professional electrician, you too can spend hundreds of hours building a home battery system you could just buy for $20k, but is less reliable.

pbasista 2 days ago

> spend hundreds of hours building a home battery system

That is, in my opinion, the worst feature of this entire project. It is cool and nice and fun. But it takes a lot of time to research, acquire skills, get tools and build.

> you could just buy for $20k

I agree with a broader point but that particular price is extremely high and far from reality.

A reasonably good 18650 cell has a capacity of ~12 Wh (~3300 mAh * ~3.7 V = ~12.2 Wh). The battery mentioned in the article consists of "more than 1000" such cells. Let us assume 1200 cells. That would mean it has a capacity of ~14.4 kWh (1200 * 12).

It is possible to get a pre-assembled steel battery case on heavy-duty wheels for 16 LiFePo cells, with a modern BMS with Bluetooth and wired communication options, a touchscreen display, a circuit breaker and nice terminals for ~ $500. And it is also possible to get 16 high quality LiFePo cells with a capacity of ~300 Ah each, like EVE MB31, for significantly less than $100 each. This means that for less than ~$2000, it is possible to get all components required to assemble a fully working ~15 kWh LiFePo battery.

- That assembly would take a few hours rather than weeks.

- It will have new cells rather than used ones.

- It will be safer to use than a battery with Li-Ion cells.

- It will likely take much less space.

- It will be easy to expand.

  • volkl48 2 days ago

    Now.

    I will point out that in 2016 when they started this project, the cost of new batteries would have been multiple times higher than it is today, so it would have been a moderately more "sensible" thing to do than it currently seems.

    • pbasista 2 days ago

      Yes, of course, this cost consideration is only relevant today.

      I can imagine that ~9 years ago there might have been very little reasonably priced LiFePO4 cells available and if someone could get their hands on used 18650 cells very cheaply, it might have been a reasonable choice at the time.

      • hinkley a day ago

        Particularly if you can narrow down a couple brands where it tends to be a single cell or two that goes poopy while the rest are still good. Driving around picking up dead batteries that only have 1-2 good cells per pack is a thankless job.

    • autobodie 2 days ago

      Now what?

      • Cyphase 2 days ago

        The costs their parent mentioned are the costs now, not back when the system was originally built.

      • wholinator2 2 days ago

        It's likely just a statement of emphasis, though the correct usage would be something like, "now, something something something..." with a comma instead of a period

      • neotek 2 days ago

        "Now" as in "all of those things are true now, but they weren't when this project started ten years ago."

  • ianferrel 2 days ago

    Thanks for the all the specifics! I admit that my $20k number was a very rough "I'm sure it must be less than this" estimate because I wanted to make sure I erred on the high side for the point I was making.

  • fragmede 2 days ago

    > - It will have new cells rather than used ones.

    This is not a feature. Our Earth is a limited resource, and being able to reuse batteries instead of discarding them to the trash is a desirable property.

    • beacon294 2 days ago

      There's even more to the riddle. Lithium recycling, cost of the power loss in old cells. Power transmit cost. Cost of power generation on site.

    • nine_k 2 days ago

      Pick used EV or industrial batteries. This must be much more efficient due to a larger cell size than in laptops.

      OTOH used laptop batteries can likely be obtained for effectively zero monetary cost, while used EV or solar backup batteries still cost quite noticeable money per kWh. With laptop batteries, you pay with your time; if you for some reason have an excess supply thereof, or you just enjoy this kind of work as a pastime.

    • pbasista 2 days ago

      > Our Earth is a limited resource

      Of course. No one disputes that. I was just trying to point out that you can get better cells for less money.

      > being able to reuse batteries instead of discarding them to the trash is a desirable property

      I fully agree. No one is trying to suggest that we should discard used batteries into trash.

    • UltraSane 2 days ago

      We have LOTS of lithium

      • awwaiid 2 days ago

        Maybe we'll run out of ion?

        • nine_k 2 days ago

          Sort of. Compact NMC Li-ion cells from laptops and phones often use stuff like cobalt, supplies of which are much more limited and problematic than of lithium. The newer LiFePO4 chemistry does not use it, and, importantly, is rather hard to ignite. Its energy density per unit mass is lower, but it's not that important for stationary installations.

  • aftbit 2 days ago

    300 Ah * 3.2 V => 960 Wh ~= 1 kWh

    $80 per cell (before shipping) on the top Google product result for EVE MB31.

    That's a good bit cheaper even than when I looked last, in early 2021.

  • hinkley a day ago

    And there's a non-zero possibility he burns his house down and doesn't have anyone to sue over it.

    At least if he bought a commercial battery and it experiences a lithium fire, he might expect to file a claim against the manufacturer, or his insurance company might on his behalf.

  • mbesto 2 days ago

    You can get 15 kWh for $1,3000 if you pick up in Texas (these use EVE MB31 which usually end up testing at ~310 Ah): https://www.apexiummall.com/index.php?route=product/product&...

    It just keeps getting cheaper and cheaper every year...

    • pshirshov 2 days ago

      What 13000? Here in the EU we pay around 3-3.5K for 15 kWh.

      • pbasista 2 days ago

        I am also in the EU and last year I have purchased a YIXIANG DIY battery case and 16 EVE MB31 cells for a combined cost of less than 2000 EUR without VAT.

        It was shipped from China so I had to wait ~2 months to get it which is a disadvantage. Local warehouse stock was slightly more expensive.

cjbgkagh 2 days ago

$20K for a home battery backup for someone capable of doing DIY would be far larger than what I assume he has built here. AFAIK the cheaper end is around $340 (2016) per kWh at 20 kWh that would be $6,800. In 2025 at $100 per kWh it would be $2K. If it's worth it would largely depending on a persons post tax required rate of return and how long it would take.

  • gwbas1c 2 days ago

    I spent almost as much as that for a 2 Powerwalls and installation in 2019. (Granted, I got a 3rd back from various incentives that probably weren't available for DIY.)

    DIY (like this project) is only "worth it" if the person doing it enjoys the work or values the lessons.

    • cjbgkagh 2 days ago

      There is a spectrum of DIY and the sweet spot depends on the person. Since I'm good with electronics my sweet spot is buying premade packs.

    • [removed] 2 days ago
      [deleted]
  • adamhartenz 2 days ago

    If you took that same time, and invested it in working at Target, or Amazon etc, would you have more or less money than it would cost to buy an off-the-shelf battery? There are obviously other pros and cons.

    • Transfinity 2 days ago

      I think Target isn't the right comparison here - the skills required for this project are worth much more than minimum wage bagging groceries. If you assume something like $50 an hour (on the low end for a skilled electrician), you get to the $6800 number in the parent post pretty quickly.

      • t-3 2 days ago

        Getting certified and hired as a skilled electrician is a lot more complicated and much harder than acquiring the knowledge to be a skilled electrician. There are many people working Target-level jobs with that level of skill in some area.

      • cjbgkagh 2 days ago

        That number was from 2016 is useful in determining if it was worth it but not useful if it will be worth it staring today as the number has changed in the intervening 9 years. The number will keep changing with an estimate of $80 kWh by 2030.

    • cjbgkagh 2 days ago

      Of the three options, DIY battery packs, premade 100aH battery packs, or white glove powerwall a minimum wage earner would likely not have the skills to DIY the battery packs nor the money to pay for the powerwall.

      Battery packs are an efficient market commodity and that’s pretty hard to beat for value for money.

      Once full installations become more of a commodity then DIY with premade packs becomes less worth it.

hinkley a day ago

That guy who was gaming a bug in the lottery in New England, near as I can figure was making about $20-30 an hour for his troubles. I suspect he may have made more off of selling the movie rights than off of the lottery.

He made more than he would have working retail for sure, but maybe he could have done better with another job if he weren't fixated on sticking it to the Man.

This battery thing feels a bit like the same sort of sentiment.

That said, any task you can do while talking to a friend or binge watching a TV show cannot be accurately accounted for in cost by just how much the clock moved.

supportengineer 2 days ago

There HAS to be a way to automate this process and make it work at scale.

  • hermitShell 2 days ago

    The problem is likely cost effectiveness compared to just replacing a whole group of cells, compared to one single cell. The unit economics of getting the remaining life from single used laptop battery are not very good. There's certainly lots of potential value for someone willing to do the work, if they can afford the opportunity cost, or if a business can source extremely dirt cheap cells and cheap high skilled labor.

  • joshvm 2 days ago

    You would be amazed how many battery packs are multiple 18650s in a trenchcoat. Even EV battery packs use them. Though it does raise the question - wouldn't an old EV battery be a better solution than stripping apart laptops?

    • 0_____0 2 days ago

      There's a lot that goes into manufacturing battery packs beyond the cells. How's your thermal path to ambient in your home wall battery? How is the inter-cell thermal isolation? Is there a path for gas discharge in the event of a cell failure? Is the pack appropriately fused at the cell or module level? When a cell fails, does it take the whole pack with it, catch someone's apartment building on fire and kill a family of 5, or merely become stinky with a hotspot visible on IR?

      How good is your cell acceptance testing? Do you do X-ray inspection for defects, do ESR vs cycle and potentially destructive testing on a sample of each lot? When a module fails health checks in the field, will you know which customers to proactively contact, and which vendor to reassess?

      Yeah lots of batteries are 18650/26650 in a trenchcoat. The trenchcoats run the gamut from "good, fine" to "you will die of smoke inhalation and have a closed casket" in quality and I think that bears mentioning.

      • lifeisstillgood 2 days ago

        I get that the trenchcoat needs to be well designed and tested, but I am still flat out amazed that you both agree with “meh, most battery packs are made up of rechargeable domestic batteries you find in a kids toy”

        I just assumed there was … special stuff in there

    • ianferrel 2 days ago

      Probably, but EV batteries are large enough that there might be an industrial recycling process for them, while old laptop batteries are basically free because it's too much labor to extract useful value from them.

      • edaemon 2 days ago

        I'm pretty sure most industrial recycling methods for lithium batteries involve grinding them up, so pack size isn't as much a factor as sheer volume. I think there just wasn't much juice for the squeeze until demand from EVs made recycling worthwhile.

        Here's a video inside a recycling plant: https://www.youtube.com/watch?v=s2xrarUWVRQ

    • znpy 2 days ago

      > You would be amazed how many battery packs are multiple 18650s in a trenchcoat

      Also laptop batteries used to be many (usually three or six) 18650s in a plastic trenchcoat.

      You could literally rebuild your battery when it died, and pick the cells you liked the most. In theory you could pick higher-quality cells than those you find in the batteries sold on ebay from chinese stores. In theory.

    • Workaccount2 2 days ago

      >You would be amazed how many battery packs are multiple 18650s in a trenchcoat

      $50 of 18650s in a $500 trenchcoat with DRM protection. So wasteful.

      • 0_____0 2 days ago

        When battery packs that have a non-zero chance of literally killing your users are commonplace, it actually does make sense to vendor-lock the battery. Believe it or not there is actual engineering that goes into making batteries beyond spot welding them to an interconnect and stuffing them into $.50 of ABS enclosure.

    • mmcwilliams 2 days ago

      That depends on the problem you're trying to solve. If it's only to build a home power system, sure, but if the goal is "I want to prevent these laptop batteries from ending up in a landfill" then using an old EV battery doesn't really help you much.

    • vel0city 2 days ago

      FWIW a lot of EVs use prismatic cells, not cylinder cells. Tesla, Rivian, and Lucid use cylindrical cells. Hyundai, Volkswagen, BMW, GM, Ford, and BYD all use prismatic cells.

  • Workaccount2 2 days ago

    There is a lot of liability in sticking your name on a hodge podge of random used lithium cells.

    • dheera 2 days ago

      I feel like for home battery backup there needs to be some kind of lower energy density solution that has zero fire risk.

      Weight is not a factor for home energy storage, there is no need for lithium cells.

      • ianburrell 2 days ago

        Currently, that is LiFePO4. It is cheaper than LiPo packs used in electronics, half the energy density, twice as many charge cycles, and doesn't burst into flame. The lithium is flammable but requires external ignition.

        Larger batteries, including some electric cars, have switched.

      • bmicraft 2 days ago

        LiFePO₄ (LFP) is overwhelmingly safe and cheap. Lithium isn't the problem here exactly.

      • etskinner 2 days ago

        It seems unlikely that there's any practical chemical batteries with 0 fire risk.

        But I do think there should be home energy storage that doesn't involve chemical batteries. Where are all the pumped hydro, flywheels, and compressed air storage for consumer use?

        • mulmen 2 days ago

          There’s no perfectly safe energy storage. The danger comes from the concentration of energy. Water can cause flooding or you can drown in it. Flywheels can disintegrate into shrapnel. It’s always risk management.

      • tinbucket 2 days ago

        Weight is not a factor for home energy storage, there is no need for lithium cells.

        That depends on your living situation. I live in a third-floor apartment, so weight is very definitely a factor.

  • beAbU 2 days ago

    Yes, with cheap third world labour, the same way many other technological marvels of the modern era are "automated".

    • harvey9 2 days ago

      This can't be done remote so you will need to bring that labor to where the work is.

      • kowabungalow 2 days ago

        There's already a pipeline sending old electronics to cheap labor for possible refurbishing, recycling and/or incorrect disposal. A small percentage they repackage into replacement laptop batteries and ship back, but they could also send more of them back as a value UPS with different value add parts.

        Personally, I expect there to be a massive conversion to USB-PD as the primary power in the cellphone only regions.

      • 0xbadcafebee 2 days ago

        Building large battery arrays out of old recycled cells does not require bringing the workers to the battery cells, any more than building iPhones requires you to bring the workers to where they mine ore. Large-scale product development often involves shipping materials and half-finished products around the world multiple times.

  • idiotsecant 2 days ago

    You would never do this in a production product. You need batteries with similar internal impedances or undesirable things happen. This is the battery equivalent of the guy who welds two car front ends together and drives it around. It's cool and quirky but not a useful product for most people.

  • jsight 2 days ago

    From what I've heard, it is more economical to recycle the raw materials than to reuse small packs.

    Reuse of vehicle sized packs seems to be pretty common, though. I'd guess that a DIY home backup could be built pretty easily from used vehicle batteries.

    • garciasn 2 days ago

      The dude has a warehouse/workshop to do this work and house the system. I’m super impressed by what he’s accomplished, don’t get me wrong; but, what he’s done just isn’t viable for 99.99999999999% of people.

      Give me an array and battery system that can pull off the grid and/or array and power most of my home without me having to think a whole lot or pay a vendor thousands to install while making the total cost under $1000 and I’ll do it.

      Until then, it just isn’t financially viable when my electricity costs are well under $70/month average across the year.

      Recouping the costs for install of solar systems are estimated at 30-40 years as of 4 years ago when I researched it. I’m sorry, but that’s just not worth it for me and most others.

      • speerer 2 days ago

        I enjoyed noticing that your percentage (1×10⁻¹³) was so precise that it excluded the man himself (he is 1 in 8×10⁹).

        I don't want to detract from your point. I just wanted to appreciate the hyperbole.

        • garciasn 2 days ago

          It's April Fools, so you have to pay close attention today; glad you caught my hilarious joke.

      • jsight 2 days ago

        Sure, but it does get a lot simpler if you start from modules instead of cells. Nothing will get around the requirement to have electrical knowledge.

        Cost is always an issue. These rarely make sense from a pure $$ sense, as everything in electrical is expensive. You could burn up that $1000 budget just to get a subpanel installed.

        Usually the value proposition is some combination of savings, combined with the ability to backup critical loads. A generator could do that too, but a proper generator setup isn't cheap either, and it wouldn't save $$ at all. Battery solutions sometimes beat that.

  • numpad0 2 days ago

    Buying a used Nissan Leaf and using V2H feature in CHAdeMO is it. Or you can remove and use its well-reverse-engineered minimum nominal 24kWh semi-removable battery. But no one wants a Leaf, so there's that.

  • raincole 2 days ago

    Of course, but you will also 'scale' the safety implications.

  • rolandog 2 days ago

    Standardizing battery packs would probably help with the automation; like with USB-C.

  • dehrmann 2 days ago

    Isn't the problem with parasitic charging? Suppose you had a bunch of used 18650 cells. To scale the electronics, they'll be wired up in parallel and/or series so the charging logic can be shared, but since the batteries are wildly mismatched, it results in parasitic charging.

    • sightbroke 2 days ago

      That is why you sort them.

      Some recent research into that: https://www.sae.org/publications/technical-papers/content/20...

      You can also consider maintaining packs together to avoid complicated disassembling processes.

      • dehrmann 2 days ago

        > maintaining packs together

        (This might already be happening, but I haven't heard about it) The big thing EVs need right now is standardized battery packs. It reduces replacement cost, takes away anxiety that a replacement will exist when you need it, and enables down-cycle uses like stationary storage.

        • sightbroke 2 days ago

          I think that may be a trickier proposition than it appears.

          Certainly a standard form factor for a pack would be helpful for a specific manufacturer (similar to building multiple cars on top of the same basic frame).

          Some of the issues I think one runs into is battery chemistries are rapidly changing so even if the shape of the pack remains the same the performance of it is rather different depending on what is put inside.

          Then even with standard form and chemistry one pack to another can be rather different depending on the history of it's use (age, charge cycles, driven hard).

          There is second life storage applications currently, and still more research going into it now.

          Personally I think smarter controls and smarter diagnostic and pack sorting will be more useful.

immibis 2 days ago

You can read it the other way around: with labour and knowledge, you can save $20k.

And with even more passion and commitment and with business skills, you could earn $20k at a time.

facile3232 2 days ago

> but it really just highlights how efficient the modern supply chain is

This "efficiency" relies on the assumption of writing off the entire battery set at sale. That's not impressive at all.