Introduction
In the world of micro-electronics, every fraction of a millimeter matters. Smart cards, smart rings, medical patches, and next-generation wearables require power sources so thin they disappear into the device itself. That’s where ultra thin lithium polymer batteries (0.3mm and below) come in.
At A&S Power, we manufacture custom ultra thin lithium polymer batteries with thickness ranging from 0.1mm to 0.3mm – thin enough to fit inside a credit card or a smart ring. This guide covers everything OEM buyers need to know about ultra thin Li-Po batteries at the 0.3mm and below level.
For a complete overview of our custom battery capabilities, check out our full guide: [Custom Lithium Polymer Battery – OEM/ODM Solutions for IoT, Wearables & Medical Devices] .
What is an Ultra Thin Lithium Polymer Battery (0.3mm and Below)?
An ultra thin lithium polymer battery at the 0.3mm and below level is a specialized rechargeable cell engineered for applications where thickness is the primary constraint. These batteries sacrifice capacity for thinness – allowing devices to be thinner than ever before.
Key characteristics:
| Feature | Description |
|---|---|
| Thickness range | 0.1mm – 0.3mm |
| Capacity range | 5mAh – 50mAh |
| Voltage | 3.7V nominal |
| Shape | Fully customizable – any shape |
| Typical applications | Smart cards, smart rings, medical patches, micro wearables |
Ultra Thin Battery Thickness Guide (0.3mm and Below)
| Thickness | Common Applications | Typical Capacity |
|---|---|---|
| 0.1mm – 0.15mm | Smart cards, RFID tags, ultra-thin labels | 5-15mAh |
| 0.2mm | Smart rings, micro wearables, NFC devices | 10-25mAh |
| 0.25mm – 0.3mm | Medical patches, fitness sensors, micro IoT | 20-50mAh |
⚠️ Key design reality: At 0.3mm and below, capacity is extremely limited. These batteries are designed for ultra-low-power devices – not for smartphones, smartwatches, or standard wearables.
Applications for Ultra Thin Batteries (0.3mm and Below)
| Industry | Applications | Why Ultra Thin |
|---|---|---|
| Smart Cards | Payment cards, access cards, smart ID cards, crypto cards | Must fit into standard card thickness (0.76mm) |
| Smart Rings | Fitness rings, payment rings, authentication rings | Extremely compact form factor |
| Medical Devices | Smart patches, continuous glucose monitors, ECG patches | Patient comfort requires minimal thickness |
| Micro Wearables | Smart jewelry, micro sensors, discreet monitoring devices | Must be virtually invisible |
| RFID/NFC | Smart labels, inventory tags, contactless authentication | Integration into labels and cards |
Customization Options for Ultra Thin Batteries (0.3mm and Below)
1. Custom Thickness
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0.1mm, 0.15mm, 0.2mm, 0.25mm, 0.3mm – select your target thickness
2. Custom Shape
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Any shape – rectangular, square, circular, or custom geometry
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Match your device‘s internal space exactly
3. Custom Capacity
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5mAh – 50mAh – match your device’s power consumption profile
4. Custom Terminals
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Ultra-thin flat contacts for card integration
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Wire leads with minimal thickness
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Solder pads for direct PCB mounting
5. Custom Labeling
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OEM branding with your logo and product information
6. Protection
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Built-in PCM (Protection Circuit Module) in ultra-compact form
Design Considerations for Ultra Thin Batteries (0.3mm and Below)
1. Capacity is extremely limited
At 0.3mm, a battery‘s capacity is measured in single-digit mAh. Design your device for ultra-low power consumption.
2. Power consumption must be minimized
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Use low-power MCUs and sensors
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Optimize software for power efficiency
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Use intermittent operation (wake up, measure, transmit, sleep)
3. Mechanical integration is critical
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Ultra thin batteries are fragile – design mechanical protection
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Consider lamination or encapsulation for durability
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Avoid bending stress on the battery area
4. Thermal management
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Ultra thin batteries have minimal thermal mass
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Avoid high discharge rates
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Design for low current draw
5. Shelf life considerations
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Ultra thin batteries have limited capacity – they may lose charge during long storage
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Storage time affects availability (capacity loss is permanent)
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Consider your supply chain timeline when ordering
Ultra Thin Battery vs Standard Li-Po – What‘s the Difference?
| Feature | Ultra Thin (0.1-0.3mm) | Standard Li-Po (3-6mm) |
|---|---|---|
| Thickness | 0.1mm – 0.3mm | 3.0mm – 6.0mm |
| Capacity | 5-50mAh | 100-5,000mAh+ |
| Applications | Smart cards, smart rings | Smartphones, wearables, speakers |
| Power consumption | Ultra-low power required | Standard power consumption |
| Mechanical protection | Critical – very fragile | Less critical |
Frequently Asked Questions
1. How thin can a lithium polymer battery be?
The thinnest commercially available lithium polymer batteries are 0.1mm thick. At A&S Power, we manufacture batteries as thin as 0.1mm.
2. What is the capacity of a 0.2mm ultra thin battery?
A 0.2mm battery typically provides 10-25mAh capacity, depending on the surface area.
3. Can ultra thin batteries be used in smart cards?
Yes. This is one of the primary applications for 0.2mm-0.3mm batteries.
4. Are ultra thin batteries rechargeable?
Yes. They are rechargeable lithium polymer batteries with 300-500 cycle life.
5. What is the cycle life of a 0.3mm ultra thin battery?
Typically 300-500 charge cycles under normal, low-current use.
6. Can I get custom labeling on ultra thin batteries?
Yes. We provide full OEM labeling services.
7. How long do ultra thin batteries last on the shelf?
Shelf life varies by storage conditions. We recommend storing at 40-60% charge in a cool, dry place. Consult our engineering team for specific storage recommendations based on your project timeline.
Custom Ultra Thin Lithium Polymer Batteries (0.3mm and Below) from A&S Power
At A&S Power, we specialize in manufacturing custom ultra thin lithium polymer batteries at the 0.3mm and below level for OEM buyers. Whether you need a 0.1mm cell for a smart card or a 0.3mm battery for a medical patch, we deliver tailored solutions.
✅ Thickness from 0.1mm to 0.3mm
✅ Custom shapes and sizes
✅ OEM labeling and packaging
✅ UL, CE, RoHS, and UN38.3 certification
✅ Engineering support from concept to production
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Dongguan A&S Power Technology Co., Limited.
Building 1, No. 2, Keji 9th Road, Songshan Lake, Dongguan, Guangdong, China
📞 +86 137 1383 1631 | ✉ info@enerbe.net