Connecting 18650 batteries in series is a great way to increase the voltage in your battery pack. By wiring batteries in series, you combine their individual voltages to produce a higher total voltage output.

For example, connecting two 3.7V 18650 lithium-ion batteries in series produces 7.4V. This stepped up voltage can power all kinds of electronics projects.

In this comprehensive guide, as a professional 18650 pil packs manufacturer, I’ll walk you through everything you need to know to safely connect 18650 batteries in series.

Why Connect 18650 Batteries in Series?

There are two main reasons you might want to hook up 18650s in series:

1. Increase Total Voltage

Like I mentioned earlier, connecting batteries in series sums their individual voltages.

So if you need to power a project that requires more voltage than a single lithium-ion cell can provide, wiring 18650s in series is the way to go.

For instance, most multi-cell vape mods run off two 18650 batteries in series to achieve 7-8V.

2. Retain Capacity

Wiring in series combines voltage while retaining capacity (mAh).

Four 2500mAh cells connected in series still provide 2500mAh, just stepped up to 14.8V.

This makes series arrangements perfect for building high-voltage battery packs with decent capacities.

Step-By-Step Guide: How to Connect 18650 Batteries in Series

Connecting 18650 battery cells in series is easy as long as you follow proper precautions.

Here’s a step-by-step walkthrough:

Things You’ll Need

• 18650 batteries
• Battery holder
• Hookup wire
• Wire stripper
• Havya
• Lehim
• Multimetre
• Hot glue gun

Make sure all your batteries match in terms of chemistry, capacity, and voltage. Mismatched cells can cause serious issues.

I highly recommend using a battery holder to securely hold each cell. These cheap plastic carriers prevent short circuits and make soldering way easier.

1. Insert Batteries Into Holders

Start by snapping each 18650 cell into its own battery holder, maintaining the same orientation across all holders.

The raised nipple on one end of the battery indicates positive. Make sure they all point the same direction.

2. Connect First Battery’s Positive Terminal

Take your first battery and lightly strip one end of a piece of hookup wire.

Twist the exposed strands together to prevent fraying. Then tin the end of the wire with a bit of solder.

This helps the wire adhere to surfaces during soldering.

Cut the wire to length if needed and solder it to the positive terminal of your first battery.

Make sure you heat the surface enough to melt the solder. Don’t apply heat too long or you risk damaging the innards of the cell.

3. Bridge Positive to Negative Terminals

Now grab your second battery in the series.

Strip and tin the other end of your hookup wire like before. Carefully solder it to the negative nickel strip on the top of your second cell.

This bridges power from the positive end of battery #1 to the negative terminal of battery #2.

4. Connect Remaining Batteries

To add more 18650s to your series string, simply bridge additional cells one by one.

Connect the negative strip of battery #2 to the positive nipple of battery #3.

Then solder the negative terminal of battery #3 to positive end of battery #4.

Keep leapfrogging your hookup wire to link each successive cell.

5. Terminate Final Battery

Once your last battery is soldered into the sequence, you need to terminate the open end.

I recommend terminating both the positive lead from battery #1 AND the negative terminal of your final battery.

That way, you can tap voltage from either end of the pack. Just make sure the two terminals never touch!

6. Test Voltage and Ensure Protection Circuitry

Before sealing up your battery pack, use a multimeter to verify overall voltage.

For example, four 18650 lithium-ions in series should give ~14.8V.

You’ll also want to implement over/undervoltage, short circuit, and thermal protection to prevent catastrophe if something goes wrong!

Once you validate proper voltage—and test protection measures—seal the assembly with hot glue or heat shrink wrap.

And that’s it! With proper care, your series 18650 battery pack will perform for years to come.

FAQs About Connecting 18650 Batteries in Series

Here are answers to some of the most common questions people have about hooking up lithium-ion batteries in series configurations:

Are There Any Downsides to Series Arrangements?

The main risk of series battery packs is cell imbalance.

If one battery drains faster than the others, it can drop below threshold voltage first. That cell ends up getting reverse charged—which can damage the innards.

Balancing circuits help mitigate this problem by shunting excess power around weaker cells.

How Many 18650 Batteries Can Be Connected in Series?

Hobbyists have built up some monster multi-cell packs, but things tend to work best in the 3-8 battery range.

Voltage climbs rapidly. So does the catastrophic failure risk if something shorts or overheats!

What Applications Use 18650s Wired in Series?

Vape mods, high-powered flashlights, and even electric bikes often use lithium-ion cells strung together in series.

These arrangements step up voltage while retaining sufficient current capabilities. Just be sure your device can handle the amperage!

What About Running 18650s in Parallel?

You sure can! Parallel arrangements maintain ~3.7V nominal voltage while multiplying capacity.

Just make sure you balance the cells and watch out for potentially massive current surges on shorts.

Do I Need Special BMS Boards or Wiring?

For small hobby packs, simple wire jumpers and hobby chargers/balancers work fine.

But larger professional setups —like electric bike batteries— absolutely require proper battery management systems to prevent catastrophe.

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I hope this guide gave you a good overview of hooking up 18650 lithium-ion batteries in series configurations.

The basic process involves:

• Physically bridging positive to negative terminals cell-to-cell
• Making good solder connections
• Verifying overall voltage
• Incorporating protection circuits

Series arrangements step up voltage for higher power. Just be cautious, stick to tested electronics principles, and you’ll be in good shape!

And as always, reach out if you have any questions about safely connecting these versatile little cylindrical cells.

Lithium-ion 18650 batteries are extremely common these days. You can find them powering laptops, cordless power tools, electric vehicles, flashlights, vapes, and more.

But over time, these batteries slowly lose capacity and efficiency. And improper handling or storage can cause them to fail unexpectedly.

That’s why it’s so important to check 18650 battery health. Testing your 18650s gives you peace of mind that they’ll perform when you need them.

In this guide, as a professional 18650 pil manufacturer, I’ll walk you through 5 methods for checking 18650 battery health in 2025.

Why You Should Check 18650 Health

Before jumping into the test methods, let me quickly explain why checking battery health is so critical.

Safety – Faulty or damaged batteries can overheat or even explode. Testing 18650s minimizes safety issues.

Performance – Healthy batteries deliver full power. Checking batteries ensures optimal device performance.

Cost Savings – Replacing dead batteries gets expensive. Testing lets you swap weak cells before they die.

Reliability – No one wants their device to die without warning. Checking battery health prevents unexpected failures.

Environmental Impact – Properly maintaining batteries reduces e-waste from premature replacements.

Now let’s look at 5 ways to evaluate the health of 18650 lithium-ion cells in 2025.

How to Check 18650 Battery Health

Method #1 – Visual Inspection

I always start my 18650 battery check with a simple visual inspection. Here’s what you need to look out for:

• Leaking or corrosion – Either of these are signs of a damaged separator or vent. Recycle the cell.
• Dents or cracks – Physical damage compromises integrity. Don’t risk it.
• Discoloration – Dark spots indicate internal issues. Discard to be safe.
• Raised top or sides – A bulging battery contains gas. Danger! Replace immediately.

As long as the battery wrapper is intact with no visible flaws, it will likely pass the remaining tests.

Method #2 – Voltage Testing

The next step is to test voltage using a digital multimeter.

Set your multimeter to DC voltage. Place the black probe on the battery’s negative terminal. Touch the red probe to the positive terminal.

A quality 18650 battery will maintain a charge above 3.6v even after storage. Here is how to interpret voltage readings:

• 3.6 – 4.2v = Good
• 3.3 – 3.6v = Marginal
• Under 3.3v = Replace

If you get less than 3.6v, the battery has low capacity. Any reading under 3.3v indicates a nearly dead cell.

Method #3 – Internal Resistance Testing

Internal resistance (IR) indicates power loss within a battery during use. As batteries age, IR creeps up reducing performance.

Specialized testers like the Xtar VP4 Plus display IR readings for each battery. For a ballpark figure without a dedicated tester, use this simple method:

Fully charge the battery and note the voltage. Then attach a load like an LED flashlight. Check voltage again after 30 seconds under load.

Subtract loaded voltage from resting voltage. The difference approximates IR.

Here are rough IR guidelines for 18650 lithium-ion batteries:

• 0 – 50 mOhms = Great
• 50 – 100 mOhms = Good
• 100 – 150 mOhms = Fair
• 150+ mOhms = Weak (replace)

Higher internal resistance accelerates capacity loss. But even batteries with fair IR (100-150) can still be useful.

Method #4 – Capacity Testing

Knowing a battery’s actual capacity compared to its rating tells you a lot about its health.

Dedicated battery testers like the SkyRC MC3000 discharge batteries while logging capacity. But you can get a ballpark capacity figure using a basic charger and multimeter.

Fully charge the battery. Place it under a 1-2 amp load until depleted to 2.8v. Make sure discharged capacity is at least 70% of the advertised capacity.

For example, a genuine 2600mAh battery should deliver around 1800mAh or more before hitting 2.8v.

I don’t recommend reusing 18650s with less than 70% remaining capacity. Performance and lifespan will be disappointing.

Method #5 – Rechargeable Cycles

Capacity loss accelerates near the end of a lithium-ion battery’s lifespan. By 200-300 cycles, capacity often drops below 70% on 18650s.

If you know the cell’s cycle count, keep it under 300. Estimating cycle count is tricky otherwise. Just use capacity testing instead to make retirement decisions.

But if you’re seeing other health problems before 200 cycles, the cell likely has a defect – replace it. Good lithium-ion cells last 300+ cycles.

Bonus: Separate & Label Batteries

Once you’ve checked battery health, store and use resurrected 18650 cells mindfully:

• Segregate tested batteries from untested stock
• Label good batteries by letter or number codes
• Never mix weak and strong batteries in devices
• Retire if capacity drops under 70%

Following those tips minimizes headaches from battery failures down the road.

Carefully checking and maintaining your 18650 lithium-ion cells gives you peace of mind that your devices will work when needed.

If you invest 15-20 minutes testing 18650 health every 6 months using the methods I shared today, you’ll get years of optimal performance.

So grab your multimeter and get cracking on those old laptop batteries – your electric skateboard will thank you! Let me know in the comments how battery testing goes.

Knowing the capacity of an 18650 lithium-ion battery is crucial for properly powering devices and effectively managing multi-cell battery packs. But determining capacity takes a bit more thought than reading the label on an 18650. In this comprehensive guide, I’ll walk through several key methods for accurately calculating 18650 capacity.

An 18650 battery’s capacity indicates how much electric charge it can deliver, measured in milliampere-hours (mAh) or ampere-hours (Ah). But contrary to what the label states, an 18650’s real-world capacity varies significantly based on the discharge current. To find usable capacity, you’ll need to account for this load-dependency.

Why an 18650’s Rated and Actual Capacity Differs

Most 18650s have a capacity rating printed on their casing, typically between 1500mAh to 3500mAh. This number represents the cell’s capacity when discharged at a low, standardized current, around 0.2C (C being the cell’s rated capacity).

Discharging at 0.2C produces the highest possible capacity. But in practice, devices often draw much more current, which reduces an 18650’s usable capacity due to several factors:

Concentration Polarization

As lithium-ions flow through an 18650 during discharge, concentration depletion regions start forming near the electrodes. The cell tries to diffuse more ions to compensate, but can’t keep up at higher currents, lowering capacity.

Ohmic Polarization

The internal resistance of an 18650 causes a voltage drop during current flow, reaching the cut-off voltage faster, ending discharge prematurely.

Rate Capability

18650s use insertion compounds that have limited sites for lithium-ions to enter. A high discharge rate reduces the amount of stored charge they can accept.

Accounting for these effects requires testing to find the actual usable capacity based on your load current.

Calculating 18650 Capacity Based on Discharge Rate

While the rated capacity is helpful for comparison, finding an 18650’s real-world runtime requires calculating the usable capacity at your specific discharge current. There are several ways to determine this.

Use a discharge curve

Reputable battery manufacturers provide discharge characteristic curves in their 18650 datasheets. These graphs show tested capacity levels across various constant discharge currents, out to a defined cut-off voltage.

With this data you can closely estimate capacity at different currents. However, few companies provide these detailed curves.

Use an online 18650 capacity calculator

There are online Li-ion battery calculators that estimate capacity based on discharge rate using archived test data. While not as precise as testing your own cell, it gives a good approximation without laboratory equipment.

Test with a programmable load

The most accurate way to find the real capacity is to test your specific 18650 cell using a programmable electronic load or battery analyzer.

These devices can safely discharge an 18650 at a steady, defined current while logging voltage over time. They discharge down to a specified cut-off voltage, then integrate current to calculate actual capacity.

Most analyzers and smart chargers have built-in discharge testing. For DIY testing, you can use a variable resistor load bank. Just ensure proper protections are in place.

While testing gives the true capacity, it requires an initial equipment investment and additional time.

Consider a safety margin

When sizing a multi-cell battery pack, best practice is to derate the per-cell capacity by 20%. This guards against over-discharging due to variations between cells and capacity loss from aging.

For high-power draws, some designers further derate by 10% to account for temperature effects in real-world use. It’s better to have slightly more capacity than needed rather than run too close to the edge.

Key Factors That Reduce 18650 Capacity

While testing gives the most accurate capacity measure, several variables beyond just discharge rate can reduce an 18650’s usable capacity:

Low temperatures

Lithium-ion cells lose capacity in cold temperatures due to increased internal resistance and slower chemical diffusion rates. Usable capacity can drop by 50% or more below freezing.

High temperatures

Capacity also diminishes above room temperature. Around 45°C, usable capacity decreases up to 20%. At 60°C, capacity can fall by 35%.

Age and cycling

With repeated charge/discharge cycles, lithium-ions lose the ability to properly intercalate into the electrodes, causing permanent capacity fade over an 18650’s lifespan.

Voltage requirements

Device cut-off voltage affects usable capacity. Capacity continues decreasing past 3.0V, so a 2.5V cut-off yields lower capacity than 3.0V. Always size packs based on the system’s cut-off voltage.

C-Rate

Usable capacity varies significantly across discharge rates. A high current can decrease capacity well below 50% of the low-rate rating. Check discharge curves when selecting cells.

By understanding how these factors influence capacity, you can more accurately predict runtime for a given application and operating conditions.

Best Practices For Optimizing 18650 Capacity

While testing and calculations provide the working capacity, there are several ways to help maximize potential lifespan and runtime from your 18650 cells:

• Carefully select cells to match required discharge rates
• Use lower discharge currents when allowable
• Avoid extreme temperature exposure
• Employ active or passive cooling methods
• Prevent fully charging to >4.10V/cell
• Avoid over-discharging below 2.5V/cell
• Utilize balanced battery management
• Slightly oversize pack capacity as a safety factor

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Determining the real-world capacity of an 18650 lithium-ion cell involves more than reading the label. By accounting for discharge rate, temperature, age, and other factors, you can dial in the usable capacity to properly size packs and accurately estimate runtime. Matching cells to loads, monitoring voltage limits, and maintaining ideal operating conditions helps unlock an 18650’s full potential.

Lithium-ion 18650 batteries have become incredibly popular over the last few years. Thanks to their high capacity and energy density, 18650s are used to power everything from laptops and power tools to electric vehicles.

But with their rise in popularity comes more questions from consumers. One of the most common is:

Can you charge 18650 batteries with usb?

As a professional 18650 pil manufacturer, I’ll answer that question in detail below. But first, let’s go over the basics of 18650 batteries.

What Is an 18650 Battery?

18650 isn’t some funky model number or code name. It simply refers to the size of the lithium-ion cell:

• 18mm diameter
• 65mm tall

So any cylindrical lithium-ion battery that shares those dimensions is considered an 18650 cell.

In terms of performance, 18650s have a nominal voltage between 3.6V and 3.7V. And capacities generally range from 2,000mAh all the way up to 3,500mAh.

This combination of compact size, high voltage, and energy density is why 18650s have become the battery of choice for so many devices. From laptop battery packs to high-powered flashlights, 18650s can handle applications that demand lots of portable power.

Now let’s get into the question at hand: using USB to charge 18650 batteries.

Can You Charge an 18650 Battery Over USB?

The short answer? Yes, you can charge an 18650 lithium-ion battery through a USB port.

However, there are a few important caveats to going this route. Below, I’ll break down the pros, cons, options, and best practices for charging 18650 batteries with USB.

The Pros of USB Charging

USB charging offers a few potential benefits:

• Convenience: Nearly all modern gadgets — from phones to battery packs to laptops — charge over USB. So being able to top up your removable 18650s using existing cables and chargers is handy.
• Availability: You can find a USB port just about anywhere, from power banks to computers to wall adapters. So if you need to give your battery a quick boost, a USB connection is often within reach.
• Safety: Unlike makeshift approaches like connecting batteries to 9v adapters, USB charging was designed specifically for lithium-ion batteries. So as long as best practices are followed (more below), USB charging does not compromise the safety of 18650 cells.

So USB can indeed be a viable way to charge 18650 batteries. But there are some downsides to keep in mind.

The Cons of USB Charging

While convenient, charging 18650 batteries through USB has a few limitations:

• Slow charge rates: USB ports max out at 2.1A (for USB-C) or 2.4A (for Qualcomm Quick Charge). That’s sufficient for smaller lithium-ion cells. But 18650 battery capacities call for chargers capable of 3A or higher for optimal charge times. So USB charging will be slower.
• Power limitations: The total wattage that can be drawn from a USB port tops out between 12-15 watts. Again, slower charging compared to dedicated 18650 chargers.
• No overcharge protection: Dedicated 18650 chargers cut power once a battery reaches 4.2V to prevent damage from overcharging. USB ports supply continuous power, so overcharging is possible if batteries aren’t closely monitored.

The limited power delivery and lack of overcharge protection remain the two biggest pitfalls of charging 18650 batteries via USB.

Fortunately, recent tech developments help mitigate those potential issues. Next I’ll explain the safest options for USB charging 18650 batteries.

Safest Ways To Charge 18650 Batteries Over USB

While USB charging comes with caveats, following a few best practices makes the method reasonably safe:

1. Use Protected 18650 Batteries

Protected 18650 batteries have an extra circuit board attached to the negative terminal. This protective PCB shuts down power to prevent over-discharge and overcharge damage.

So if you plan to charge via USB, using protected cells adds a critical safeguard against overcharging. Just be sure to buy quality protected batteries from reputable brands like KeepPower, Olight or Vapcell. Cheap cells may have protections that fail to trip when needed.

2. Manually Monitor charge

When charging 18650s through USB, manually monitor battery voltage to prevent potential overcharge. Simply use a voltmeter to periodically check if batteries are approaching 4.2V. Once nearing full charge, remove batteries from the USB source.

While a bit tedious, monitoring battery voltage ensures safe USB charging. And for infrequent charging, it’s an easy safeguard. For more frequent charging, the next option is more convenient.

3. Use Smart Chargers

Recently, purpose-built USB 18650 smart chargers have emerged. These smart chargers have the necessary protections built in to safely charge 18650s via USB.

For example, this model from Xtar automatically stops charging once batteries reach 4.2V.

Other smart USB chargers for 18650 batteries include:

• Nitecore F1
• Olight UC Magnetic USB Charger
• Vapcell S4 Plus

These smart chargers are safe, convenient options for USB charging. Just be sure to buy from a reputable brand. Quality varies widely with USB chargers.

So those are the three best practices I recommend when charging 18650 batteries over USB:

1. Use protected cells
2. Manually monitor voltage
3. Employ smart chargers

Following those simple guidelines will make USB charging nearly as safe as dedicated 18650 battery chargers.

Just remember: slower charge times and lower power delivery remain inherent USB limitations. So while periodically using USB to top up 18650s is fine, I don’t recommend it as a daily charging solution.

Wrapping Up

Lithium-ion 18650 batteries offer tremendous performance potential in a compact cylindrical package. And the ability to charge them via ubiquitous USB ports adds to their versatility and convenience.

So can you charge 18650 batteries with USB? Absolutely. Just be sure to take the proper precautions.

I hope this post shed some light on safely charging 18650 lithium batteries over USB. But if you have any other questions, let me know in the comments section below!

Can you solder 18650 batteries? Well, you technically can. But should you? That’s a whole different question.

In this detailed guide, as a professional 18650 pil manufacturer, I’ll cover everything you need to know about soldering 18650 lithium-ion batteries. You’ll learn the pros and cons, safety precautions, tips for minimizing damage, and more.

Can You Solder 18650 Batteries?

First things first – yes, you can solder 18650 batteries. The key is using a high-powered soldering iron that gets the job done quickly. This minimizes excess heat that could damage the batteries.

However, most battery experts agree that soldering should only be done as a last resort. Spot welding 18650 cells is a much better option. The intense, momentary heat of spot welding does not penetrate far into the cell. Soldering takes longer, putting more total heat into the battery.

So while 18650 soldering is possible, it risks damaging the cells and shortening their lifespan. It can also be dangerous if done improperly. Stick to spot welding when possible.

The Dangers of Soldering Lithium-Ion Batteries

Why is soldering 18650 cells so controversial in the first place?

In short – the risk of damage or explosion.

Lithium-ion batteries contain flammable electrolyte liquid. Excessive heat can damage the protective seals inside the battery. If the electrolyte leaks out and gets exposed to air, catastrophic failure can occur.

Worst case scenario? Thermal runaway leading to an explosive fire. Yikes!

And the more batteries you connect together, the greater the potential disaster. A single overheated cell can set off a chain reaction through an entire battery pack.

So soldering definitely requires caution. Even if done properly, it may degrade battery performance and lifespan over time.

Tips for Soldering 18650 Batteries

If you MUST solder 18650s together, here are some tips to minimize cell damage:

• Use a 100W+ soldering iron. Higher wattage means faster heat transfer. Spend as little time as possible in contact with each battery terminal.
• Work quickly. Get your solder joints completed in 2-3 seconds max. The longer your iron touches the cell, the more heat soaks in.
• Apply plenty of flux. Flux improves heat conduction and promotes proper bonding.
• Let cells cool completely between solder connections. Give them a minute or two to return to room temperature.
• Visually inspect each solder joint. Look for complete bonding and any signs of overheating damage.
• Charge and test capacity after construction. Compare to the rated capacity to estimate impact of soldering heat.
• Allow extra spacing between parallel rows of batteries. Airflow helps cooling during charging/discharging.

Following these precautions will minimize, but not eliminate, damage when soldering 18650 lithium-ion cells.

Pros and Cons of Soldering vs. Spot Welding

Let’s compare the upsides and downsides of these two methods for connecting 18650 batteries:

Soldering 18650 Cells

Pros

• Allows precise joint placement
• Strong and permanent electrical bonds
• Enables complex wiring layouts

Cons

• Risk of seal/separator damage from excess heat
• Inconsistent damage between cells
• Additional aging and capacity loss
• Danger of leakage/fires if overheated

Spot Welding 18650 Cells

Pros

• Extremely fast heat application
• Minimal heating impact on cells
• Consistent results between cells
• Automated process for mass production

Cons

• Requires expensive specialty equipment
• Some layouts harder to arrange
• Can’t access welds for repairs
• Possible failure over time due to metal fatigue

As you can see, both options have their merits. But safety and performance strongly favor spot welding for most 18650 battery projects.

Are Soldered 18650 Packs Safe To Use?

Once constructed, is a soldered 18650 pack relatively safe? Or should you expect problems down the road?

The answer depends on a couple key factors:

• Workmanship quality – Were joints overheated? Are there visible signs of damage? Proper technique is critical.
• Charge/discharge monitoring – Use a balance charger an monitor voltage closely. Imbalances can cause individual cell failures.
• Quality reputable cells – Lower-end no-name cells may have less heat resilience and protective safeguards built in. Stick with trusted brands.

If due diligence is followed during AND after construction, soldered packs can deliver acceptable performance and safety. But small flaws can be ticking time bombs. Lifespan and reliability take hits compared to spot welding.

For lower-risk results, engineering best practices still recommend ditching the soldering iron!

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While soldering 18650 lithium cells is possible, safety concerns rightfully make it controversial. Risks of damage and cell failure only increase when assembling multi-cell packs.

For one-off hobby projects by experienced builders, soldering may be ‘good enough’. But performance and long-term reliability will suffer compared to proper spot welding. And danger is always lurking if mistakes are made.

When electrical and thermal management is critical, skip the soldering iron. Search around for makerspaces or battery rebuilders with spot welding equipment. Or invest in your own welder if you plan to build many custom battery packs.

Thanks for reading! I hope this guide gave some thoughtful answers on whether 18650 soldering makes sense or not. Stay safe, and happy building!