In June 2025, Anker issued a global recall of over 1.1 million power banks due to fire risks caused by overheating lithium batteries. Anker power banks recalled, this high-profile case underscores the urgent need for continuous improvement in manufacturing. When working across borders on global product development, brands must prioritize not only innovation but also rigorous battery safety design, proactive power bank compliance, and expert-led custom battery engineering. These practices form the backbone of safer, scalable, and trustworthy power solutions.
1. Safety Failures Start in Design, Not Just Manufacturing
Although the recall addressed end-user danger, its root causes typically begin in early-stage engineering. That’s why improvement should be continuous in manufacturing. Continuous enhancement in manufacturing must include the blueprint phase, not just the factory floor. Problems like insufficient thermal management, weak BMS coordination, and loose supplier standards often go unnoticed until failure occurs. By embedding battery safety design into your development process from the outset, risks can be dramatically reduced. Embracing continuous improvement concepts from design to production can help mitigate these issues.
2. The Cost of Compliance Oversight
The global nature of tech products means compliance failures carry worldwide consequences. Companies that treat power bank compliance as an afterthought may face not just fines and recalls, but bans from major shipping channels and irreparable brand damage. As part of our global product development approach, we help clients build products that are UN38.3-, CE-, and UL-ready — long before they reach customs, maintaining continuous improvement efforts that prevent manufacturing lapses.
3. Recalls Can Destroy Trust — Or Spark Change
Anker’s swift recall and replacement effort helped mitigate backlash. Still, consumer confidence took a hit. For some companies, these crises become catalysts for positive change by encouraging continuous improvement within manufacturing processes, faster iterations, higher internal standards, and greater accountability. In the long term, brands that evolve after mistakes often emerge stronger. Processes aimed at continuous manufacturing improvements are key for rebuilding trust.
4. Why Custom Battery Engineering Makes a Difference
Too often, off-the-shelf battery packs prioritize cost over quality. By contrast, custom battery engineering gives you control over critical variables: heat dissipation, PCB layout, cell quality, and casing durability. Our engineers optimize for both safety and performance — from flame-retardant materials to redundant protective circuitry. Ensuring that methods for continuous improvement within manufacturing settings are considered across projects helps reduce risk and raise consistency.
5. How WokooDesign Supports Safe, Scalable Solutions
As a forward-thinking power bank design company, WokooDesign guides clients through:
- CAD and FMEA-backed battery safety design reviews
- International power bank compliance pre-checks
- Functional prototypes for testing in realistic conditions
- End-to-end custom battery engineering built for global product development
All of this is done with one principle in mind: embedding continuous improvement in manufacturing into every product we help launch. Continuous adaptation in manufacturing ensures we remain on the cutting edge.
Let’s build better batteries — smarter, safer, and globally compliant.
Contact WokooDesign to explore how we can help your next innovation avoid the pitfalls and lead with confidence.
