One of the projects I worked on was a battery retrofit solution for Bossard’s SmartBin system, an intelligent inventory management solution for industrial fasteners. The existing battery solution was both expensive and environmentally problematic, affecting thousands of units deployed globally.
The Battery Retrofit Project
Working as part of the project team, we explored alternative battery technologies to find a more sustainable and cost-effective solution. The approach involved:
- Testing & Validation: Conducting tests with many different technologies that may solve this problem
- Specific Research & Analysis: Evaluating different battery chemistries (Li-ion variants, LiFePO4) for performance, cost, and environmental impact
- Stakeholder Interviews: Understanding requirements from engineering and business perspectives
- Solution Development: Designing and prototyping the retrofit solution with focus on backward compatibility
The final solution used lithium iron phosphate (LiFePO4) rechargeable batteries, achieving impressive results:
- 50% reduction in battery costs
- 16% reduction in CO2 emissions
- Extended service life from 5 to 20 years
- Planned deployment across over 100,000 SmartBin units globally
The project became the first from the Exploration Lab to advance to industrialization, with rollout scheduled for early 2026. You can read more in Bossard’s press release.
The ETH Exploration Lab
This project was part of my participation in the ETH Exploration Lab - a selective interdisciplinary program designed to find and validate innovation opportunities at the intersection of academia and industry.
The 2024 cohort brought together 14 students working with four major Swiss companies:
- Bossard AG - Assembly and fastening technology
- Bühler AG - Food processing and advanced materials
- VAT Group AG - Vacuum valve technology
- V-ZUG AG - Household appliances
What We Did
As students, we were testing disruptive ideas through rapid, structured exploration with the goal of driving forward through innovation. My responsibilities included:
Innovation & Design
- Applying structured innovation and creativity methods to explore technical feasibility
- Designing mechanical components using CAD tools and creating early-stage prototypes
- Developing electronic circuit designs for integrated system testing
Software Development
- Programming primarily in Python for data processing and visualization
- Developing AI-based applications for image, text, and data analysis
- Creating interfaces and conversational assistants
Prototyping & Fabrication
- Rapid prototyping using 3D printing, laser cutting, and other techniques
- Integrating hardware and software components for system testing
Communication & Management
- Conducting interviews with stakeholders to define requirements and evaluate use cases
- Planning project timelines and deliverables within team-based frameworks
- Presenting results to project stakeholders and C-level leadership
- Documenting progress in professional reports and presentations
Why This Experience Matters
The Exploration Program provided a unique opportunity to work on real industrial challenges while still being a student. Unlike typical academic projects, these had actual business constraints, real deadlines, and tangible impact.
Impact
This program demonstrated how academic institutions and industry can create genuine innovation partnerships. Students gain hands-on experience in high-risk innovation projects and tech commercialization, while companies benefit from fresh perspectives and access to cutting-edge research.
The fact that our battery retrofit project advanced to industrialization - affecting over 100,000 units globally - shows that this model can produce real business value, not just academic exercises.
