I’m building a portable electronics product that I want to have mass-produced and sold to consumers. Besides the obvious electronic protection (overtemperature, over-/undercharge), I’m worried about physical protection.
For example, it seems li-ion batteries can in rare circumstances swell up. Should I leave some extra space to allow the battery to swell and if yes, how much? I plan on covering all sharp edges (from through holes sticking through the pcb) so they can’t cut the battery. Any other measures that I should be thinking of? Any advice or pointers to information would be greatly appreciated.