Small batteries. Big ambitions. Can lithium-ion power take flight?

Yes — small lithium-ion batteries¹ are already used in aerospace, especially for satellites, drones, and onboard systems, thanks to their high energy density², lightweight profile, and long cycle life³.

With aerospace pushing the limits of size, weight, and reliability — let's explore whether these compact powerhouses can keep up.

What makes lithium-ion batteries work for space?

In short: they punch above their weight.

Small lithium-ion batteries⁴ store more energy per gram⁵ than most other chemistries, and they can last hundreds of charge cycles⁶ with minimal degradation.

Key features:

Feature	Why It Matters in Aerospace
High energy density7	More power, less weight
Low self-discharge	Retains charge for long missions
Long cycle life8	Supports multi-year deployments
Customizable formats	Fits tight or curved compartments
Proven reliability9	Used in satellites and drones

How are they already used in aerospace?

They're not just theoretical. Lithium-ion is already in orbit.

CubeSats, drones, high-altitude balloons, and even manned space missions use small-format lithium-ion packs.

Examples include:

• CubeSats¹⁰: Compact satellites rely on lithium-ion for energy storage.
• UAVs¹¹: Unmanned aerial vehicles use high-discharge Li-ion for propulsion.
• Space probes¹²: Small backup systems use them as secondary power sources.

NASA, ESA, and commercial companies like SpaceX and Planet Labs all utilize lithium-ion cells in various spacecraft subsystems.

What challenges do aerospace applications face?

Space is brutal. Batteries have to survive it.

Lithium-ion batteries must handle temperature extremes, radiation, vacuum pressure, vibration, and zero-maintenance operation.

Main challenges:

Challenge	Risk	Mitigation
Extreme temperatures13	Cell degradation or failure	Thermal insulation & heating units
Vacuum conditions14	Electrolyte leakage, swelling	Hermetic sealing, solid-state cells
Vibration and shock	Internal shorts	Ruggedized cell packs, potting
Overcharge/overdischarge15	Thermal runaway, fire risk	Redundant BMS systems

Aerospace-grade lithium-ion packs are typically customized with multiple layers of redundancy — more sensors, better casing, smarter firmware.

Are they safe for critical aerospace missions?

With the right engineering — yes.

While lithium-ion has known safety concerns (especially with overheating), aerospace systems mitigate this through strict testing, monitoring, and safeguards.

Key safety practices:

• Advanced Battery Management Systems (BMS)¹⁶ monitor every cell.
• Passive and active thermal control¹⁷ to keep packs in safe zones.
• UN 38.3 and IEC 62133 testing for vibration, altitude, crush, etc.
• Use of LiFePO4 or NMC chemistry with lower thermal risk.

Result: lithium-ion is trusted — but only when rigorously validated.

How do they compare to other aerospace battery types?

Compared to legacy options, lithium-ion wins on most fronts.

Battery Type	Energy Density	Cycle Life	Temp Tolerance	Cost	Aerospace Use
Lithium-ion	★★★★☆	★★★★☆	★★★☆☆	★★★☆	Satellites, UAVs
NiMH	★★☆☆☆	★★★☆☆	★★★★☆	★★★☆	Older satellites
Ag-Zn	★★★☆☆	★★☆☆☆	★★☆☆☆	★★★★★	Military only
Solid-state	★★★★★	★★★★★	★★★★★	★☆☆☆	Experimental

Small lithium-ion wins on size, weight, and maturity. But solid-state might change the game in the future.

What’s coming next for aerospace-grade lithium-ion?

The future is smaller, smarter, and safer.

Manufacturers are pushing toward semi-solid and all-solid-state lithium technologies — safer, higher capacity, and vacuum-resistant.

Emerging trends:

• Space-rated BMS chips with radiation shielding
• Self-healing separators to extend cycle life
• Flexible and printed batteries for structural integration
• Low-temp optimized chemistries for deep space

As launch costs fall and private missions rise, the demand for small, smart, rugged batteries will only grow.

Conclusion

Small lithium-ion batteries are already lifting off — literally.

From satellites to drones, they power today's aerospace missions. With smart design, they meet the tough standards of space. And the future? Even brighter — and lighter.