In today’s fast-moving world of connected technology, devices are everywhere—on our wrists, in our homes, across factory floors, and out in the field. As these smart devices take on bigger, more critical roles, their success often comes down to one deceptively simple question: How long will the battery last? Whether it’s an industrial sensor monitoring machine performance or a wearable tracking health data, battery life is no longer a “nice to have”—it’s a non-negotiable. And in many cases, it’s the difference between a successful product and one that never makes it off the shelf.
Why Battery Life Can Make—or Break—Your Product
Many connected devices live in places where plugging in regularly just isn’t an option. Think remote agriculture sensors, rugged field monitors, or wearables for continuous health tracking. In these scenarios, reliable battery power is essential—not just for convenience, but for performance, safety, and uptime.
Add in the push toward edge computing, where more data processing happens locally to reduce latency and bandwidth usage, and suddenly your power demands increase. If your device drains its battery too quickly, users won’t tolerate it. Imagine a smart sensor that needs to be charged every few days, or a controller that unpredictably goes offline—it’s not just annoying, it’s a failure in function.
Behind the scenes, subtle design decisions—like which wireless protocol you use or how memory is allocated—can dramatically affect energy use. Since most devices run without human oversight, regular recharging or battery swaps just isn’t scalable.
How We Think About Power: Design with Intent from Day One
At Twisthink, we’ve spent over 20 years designing connected devices that are built to last—literally. Whether it’s a hand pump sensor or a warehouse operations device, our goal has always been the same: build smart systems that never run out of steam.
Achieving long-lasting battery life doesn’t start with choosing a battery—it starts at square one, during the architecture and feasibility phases. That’s when we create a high-level battery model, define realistic use cases, and zero in on the major power consumers.
For example, are you designing a wireless actuator? Your model needs to account for both continuous wireless connectivity and the power spikes from actuation. From there, we simulate various usage scenarios—best-case and worst-case—to estimate energy needs, trade off options, and identify the ideal battery size and type.
And yes, we still love Excel. A spreadsheet can be a powerful starting point, letting us layer in real-world factors like battery self-discharge, temperature impact, and voltage regulator inefficiencies for a sharper, more accurate projection.
Real-World Insight: A 10-Year Battery for Remote Monitoring
When charity: water needed a connected sensor that could run for a full decade in remote, hard-to-reach locations, we focused on four key strategies:
- Ultra-low-power microcontroller for ongoing sensor monitoring.
- Complete power-down of high-drain components like the cellular radio and GPS when idle.
- Local data storage with periodic uploads, avoiding constant cellular activity.
- Smart battery pairing: A high-density, low self-depleting battery supported by a super-capacitor to handle cellular bursts without compromising battery lifespan.
The result? A reliable, low-maintenance device designed for long-term impact in the harshest of environments, keeping clean water flowing for millions.
Designing Without Compromise: How Software and Hardware Choices Extend Battery Life
Optimizing for power isn’t just about hardware. It’s about thoughtful decisions made across the entire system. It starts with choosing processors that are right-sized for the task, rather than overbuilding with unnecessary computing power. On the software side, writing power-aware code that enables deep sleep modes during inactivity can significantly reduce energy use. Pairing with the right wireless technology is equally important, since not all radio silicon is created equal—some are far more efficient than others. And when it comes to communication, minimizing data transmission overhead through smarter, leaner protocols can have a major impact on battery performance.
Through all of this, user experience should remain front and center. With intentional, system-wide design, it’s absolutely possible to create connected products that are both long-lasting and effortless to use.
Real-World Insight: Big Performance in a Tiny Power Package
For a warehouse equipment manufacturer, the challenge was delivering a high-functioning solution with ultra-low latency in a very small package. We selected Bluetooth Low Energy (BLE) and a super-capacitor, which provided:
- Ultra-fast charging in seconds
- Over 4 hours of continuous operation
- Full functionality without a traditional battery
It was a perfect match—small, lightweight, low maintenance, and high performance—keeping warehouse operations moving smoothly, safely, and efficiently.
Why It Matters: Power Planning as a Strategic Advantage
Great battery life isn’t just a feature—it’s a competitive edge. It impacts:
- Reliability: Longer runtimes build user trust and reduce failure rates.
- Maintenance: Fewer battery changes mean less downtime and lower costs.
- Customer Experience: Devices that “just work” make happier, more loyal users.
- Sustainability: Fewer batteries = less waste and greater environmental responsibility.
- Total Cost of Ownership: Smart energy choices lead to long-term savings.
Let’s Talk Power
If battery life is a make-or-break factor in your next connected product, let’s talk. Twisthink’s multidisciplinary team brings deep expertise in system design, power architecture, and wireless technologies.
Connect with us for:
- A complimentary consultation to estimate power needs or battery lifespan
- Expert guidance in battery chemistry selection and holistic power planning
Let’s design something that’s not only connected—but built to last. Click here to connect with our team.
As the Director of Technology, Matt spearheads the development of excellent solutions tailored to meet the distinct needs of each client. Matt's expertise spans a multitude of domains, including system architecture, wireless protocol design, embedded circuit design, and firmware development, among others, all of which have played pivotal roles in his success.
