Sure thing. First sketch the exoskeleton’s load paths and identify every spot where the battery cells are just hanging there. If you can make the cells part of the structural grid—say, embed them in a carbon‑fiber honeycomb panel—you’ll cut the separate support frame by a decent amount. Second, swap the standard lithium‑ion cells for a thin, high‑energy density pouch version or look into a Li‑S or solid‑state chemistry if the supply chain allows; those can shave a few kilos while keeping the same voltage. Third, think about a modular battery pack: instead of one big block, use several smaller cells that can be spread across the frame, so you keep the mass distributed and the structure doesn’t see a single heavy lump. Finally, run a quick finite‑element check on the new layout—tolerances might let you thin the skins a bit more than you’d think. That’s the baseline. Let me know what you’re actually using right now, and we can dive into numbers.

Nice, a 15 % lift off the frame is a good start. Make sure the honeycomb cells are bonded with a thermally conductive epoxy; that’ll keep the thermal paths intact. For the pouch route, keep an eye on the specific energy—most high‑energy pouches sit around 260 Wh/kg, so you’ll shave about 0.3 kWh in weight for the same capacity. Solid‑state will drop the mass even more, but check the thermal shutdown and cycling life; a quick lab test on a smaller module will flag any issues before you commit. Run the FEA and let me know the skin thickness you can afford—if you can get down to 1.5 mm without a loss of stiffness, we’re looking at a solid win. Just keep the load paths clean and don’t let the extra complexity creep in.We have a response. No formatting. Good.Nice, a 15 % lift off the frame is a good start. Make sure the honeycomb cells are bonded with a thermally conductive epoxy; that’ll keep the thermal paths intact. For the pouch route, keep an eye on the specific energy—most high‑energy pouches sit around 260 Wh/kg, so you’ll shave about 0.3 kWh in weight for the same capacity. Solid‑state will drop the mass even more, but check the thermal shutdown and cycling life; a quick lab test on a smaller module will flag any issues before you commit. Run the FEA and let me know the skin thickness you can afford—if you can get down to 1.5 mm without a loss of stiffness, we’re looking at a solid win. Just keep the load paths clean and don’t let the extra complexity creep in.

Sounds like the numbers line up. Just double‑check that the 3 mm collars don’t create a stress concentration on the joint, and keep the thermal epoxy application consistent—uniform cure is a small detail that can trip up the whole system. If the prototype runs at room temperature without a hiccup, we’ll have a solid foundation for the next sprint. Good luck, and keep the load paths tidy—no one likes a stray stress.