1.7 Million Power Banks Recalled Since March: How SolidSafe™ Solves the Problem

The Power Bank Recall Problem

Since March 2025, more than 1.7 million portable chargers were recalled worldwide.

Reports cited overheating, swelling, smoke, and even fires in products people trusted to carry with them every day.

If you’ve ever left a charger in a hot car, handed one to your kid, or packed one in your bag it shouldn’t put them at risk.

Why It's Happening

The surge in recalls is not random. It comes from pushing lithium-ion technology beyond its safe limits. As manufacturers pack higher-capacity cells into smaller, thinner designs, there is less room for error. Even tiny issues like overheated charging chips, insulation flaws, or microscopic internal shorts can trigger thermal runaway, where internal heat rapidly builds and the cell loses control.

At the core of the problem is the flammable liquid electrolyte used in almost all lithium-ion batteries. This liquid carries energy between the anode and cathode, but under stress from overheating, physical damage, or overcharging, it can vaporize, build pressure, and leak out. Once exposed to oxygen, it can ignite instantly. That is why so many reported incidents involve swelling, smoke, and fires. When the electrolyte escapes, the battery essentially becomes a small pressurized fuel source.

As devices get faster and power demands increase, manufacturers are cramming more energy into less space with thinner separators and hotter circuits. This shrinking safety margin is driving a sharp rise in recalls because a single chip failure or cell defect can turn a trusted power bank into a hazard.

How Solid-State Batteries Make Power Safer

Solid‑state batteries work differently. Instead of relying on a large amount of liquid to move energy inside the cell, they use a more stable, solid-like material that does not leak and can handle heat better. With far less flammable content inside, the risk of swelling, smoke, or fire drops dramatically. These batteries can still deliver the same performance or better in a smaller, lighter design.

Introducing SolidSafe™: The New Standard in Power Safety

SolidSafe™ is a new family of power banks designed to avoid those failures entirely.

Instead of liquid electrolyte, it uses solid-state battery cells, a safer chemistry that resists overheating, leaking, and swelling.

And it does what most power banks can’t: stay stable under extreme conditions. To prove it, we drilled a fully charged unit straight through the battery. No smoke, no swelling, no ignition.

SolidSafe™ Drilled. 
No Thermal Reaction

A typical lithium-based pack caught fire in this test. SolidSafe™ stayed stable.

Disclosure: Drill test performed on a SolidSafe™ production sample under controlled conditions by trained staff. Do not try this at home