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Will Prowse and others have documented serious problems with Battle Born batteries — overheating terminals, arcing connections, melted enclosures. Instead of a design fix, Dragonfly Energy doubled down with a technical paper claiming the failures are an intentional safety feature, then filed a lawsuit.

I'm not weighing in on the lawsuit or Will's testing. I'm an engineer with 20 years in the industry, and I wanted to look at this from a pure design and materials standpoint. What I found is a connection that's mechanically set up to fail — not from abuse, but from basic thermal expansion math that applies to every single one of these batteries from the day they're assembled.

Battle Born / Dragonfly Energy Technical Note: https://drive.google.com/file/d/1fVX4oAMpiqbzldrfmBLtPSzTysCVW9Hn/view?usp=sharing

https://youtu.be/_IHN-OK19uU

https://youtu.be/PcBZ23kmUKc