Primary Flexible Battery Market Size, Share & Trends Analysis Report By Product (Li-MnO2 Batteries, Carbon Zinc Batteries, Lithium-ion Batteries), By Applications (Smart Security and Payment Cards, Novelty Packaging, Medical Label, Others), By End Use, By Region, and Segment Forecasts - 2035

Primary Flexible Battery Market Overview

The global primary flexible battery market size was valued at USD 452.3 million in 2025 and is projected to grow from USD 478.08 million in 2026 to USD 783.15 million by 2035, at a CAGR of 5.7% from 2026 to 2035.

The Primary Flexible Battery Market is expanding as manufacturers seek ultra-thin, lightweight and conformable power sources for smart cards, connected packaging, disposable medical labels and compact electronic products. Li-MnO2 Batteries are increasingly favored where higher energy density, stable 3.0 V output and long shelf life are required, while Carbon Zinc Batteries remain attractive for very low-profile printed applications and low-current electronics. Lithium-ion Batteries also participate in specialized thin and flexible formats where form-factor requirements outweigh conventional cylindrical or prismatic designs. Current thin primary Li-MnO2 cells can achieve thickness close to 1.1 mm in selected products, energy density around 400 Wh/kg and 500 Wh/l, and operating temperatures between approximately -20°C and 60°C. Shelf life can exceed 10 years, while annual self-discharge can remain below 1% at room temperature. These properties allow flexible batteries to power devices that are difficult to accommodate with rigid coin cells, supporting the market's projected 5.7% CAGR through 2035.

The United States remains an important Primary Flexible Battery Market because of strong demand for connected medical devices, smart cards, electronic labels, RFID systems, asset-tracking applications and intelligent packaging. North America is estimated to account for approximately 31% of global demand in 2026, with the United States contributing most regional consumption. Thin primary batteries used in security and tracking products increasingly need to support intermittent RF transmission, requiring higher pulse capability than conventional low-drain printed cells. Current Li-MnO2 thin-cell formats can provide capacities from approximately 115 mAh to 1,600 mAh, depending on dimensions, while selected designs can deliver pulse current up to around 300 mA. U.S. product developers also value long storage stability because medical or security products may remain unused for several years before activation. Flexible formats therefore gain importance where a device must remain under approximately 5 mm thick while still providing dependable primary power.

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Key Findings

• Leading Product Type: Li-MnO2 Batteries are expected to hold approximately 54% market share in 2026 because 3.0 V output, high energy density and shelf life exceeding 10 years support demanding thin-device applications.
• Leading Application: Smart Security and Payment Cards are projected to account for approximately 34% of 2026 demand as powered authentication, tracking and interactive card functions require ultra-thin embedded primary batteries.
• Leading Region: North America is expected to hold approximately 31% market share in 2026, supported by connected healthcare, secure identification, asset tracking and advanced packaging applications.
• Fastest Growing Region: Asia-Pacific is projected to expand at approximately 7.2% annually through 2035 as electronics manufacturing, smart packaging and connected card production scale across major economies.
• Technology Trend: Ultra-thin Li-MnO2 formats are advancing, with current pouch cells available near 1.1 mm thickness while delivering energy density around 400 Wh/kg for compact connected products.
• Market Driver: Long-duration embedded power is strengthening demand, with selected primary thin cells retaining more than 98% of capacity after 1 year of room-temperature storage.
• Competitive Landscape: Product portfolios are broadening, with current thin-cell families offering more than 8 pre-engineered sizes and capacities ranging from approximately 115 mAh to 1,600 mAh.
• Future Outlook: The market is forecast to grow at 5.7% CAGR through 2035 as flexible electronics, medical labels, intelligent cards and connected packaging require thinner primary power sources.

Latest Trends

The strongest market trend is the transition from conventional coin cells toward thin pouch and printed battery formats that use available surface area rather than device thickness to store energy. Current Li-MnO2 thin-cell designs can be produced near 1.1 mm thickness in commercial product families, while some compact formats are promoted at even lower construction thickness depending on packaging and termination. These products provide approximately 3.0 V nominal output and energy density near 400 Wh/kg and 500 Wh/l, materially exceeding the approximately 260 Wh/kg and 300 Wh/l associated with high-performing lithium coin-cell benchmarks. This form-factor advantage is especially important for Smart Security and Payment Cards and Medical Label products, where total device thickness may need to remain only a few millimeters. Flexible battery developers are therefore focusing not only on energy density but also on tab geometry, lamination, bend tolerance and compatibility with printed electronics.

Printed and roll-to-roll battery manufacturing is another important trend. Carbon Zinc Batteries can be produced using screen-printing and lamination processes, allowing cell dimensions and shapes to be tailored to specific packaging or label requirements. Printed cell areas can range from approximately 1 cm² to 100 cm², with specific capacity near 4 mAh/cm² in established flexible zinc-manganese dioxide architectures. Current capability can range from around 0.1 mA/cm² to 2.0 mA/cm² depending on internal structure and materials. Such systems are particularly attractive for Novelty Packaging and disposable electronics because they can be integrated alongside printed antennas, sensors and displays on thin substrates. Through 2035, roll-to-roll production should become increasingly important because it allows battery manufacturing to align with the high-throughput converting processes already used for labels, cards and flexible packaging.

Market Dynamics

Driver

""Miniaturized connected products are increasing demand for thin primary power sources.""

The strongest market driver is the rapid growth of devices that need power but cannot accommodate rigid cylindrical or coin-cell batteries. Smart cards, medical labels, electronic packaging and compact tracking tags often have thickness limits below approximately 5 mm and may need to bend during handling. Thin Li-MnO2 products address this requirement by distributing active material across a larger flat area. Current commercial thin cells span capacities from approximately 115 mAh to 1,600 mAh while maintaining lightweight laminated packaging. Low self-discharge is equally important because a security card or medical device may remain on a shelf for several years before activation. Selected primary cells lose less than 1% capacity after 1 year at approximately 20°C and can provide shelf life exceeding 10 years. These characteristics make flexible primary batteries well suited to long-life connected products and support sustained market expansion.

Restraint

""Energy, bending and packaging constraints limit flexible battery design freedom.""

The primary restraint is that achieving very low thickness can reduce the total active material available for energy storage. A cell designed for only 1-2 mm thickness may need a larger footprint to provide the same capacity as a thicker conventional battery. This can create integration challenges in compact cards or labels where both area and thickness are limited. Repeated bending can also stress current collectors, laminated seals and internal electrode interfaces if the product is not engineered for the correct bend radius. Primary batteries further require reliable packaging because moisture intrusion can degrade electrochemical performance over multi-year storage. Operating temperature is another constraint, with many thin Li-MnO2 products designed around approximately -20°C to 60°C. Applications outside that window may require alternative packaging or chemistry. These technical tradeoffs can increase qualification time and limit adoption in harsh-use environments.

Opportunity

""Connected medical labels and intelligent packaging create new high-volume opportunities.""

Medical Label and Novelty Packaging applications create a significant opportunity because both sectors increasingly integrate electronics into surfaces that historically contained no battery. A smart medical label can power temperature sensing, dose reminders, adherence tracking or wireless communication while remaining attached to a package or wearable surface. Flexible primary cells are particularly suitable because products can be less than a few millimeters thick and weigh only around 1-5 grams in compact formats. Novelty Packaging can use batteries to power lights, sound, sensors or NFC-enhanced interactions for promotional and authentication purposes. Printed Carbon Zinc Batteries are attractive where current demand is low, while Li-MnO2 Batteries provide higher energy for RF transmission. Through 2035, integration with printed sensors, antennas and displays could create complete flexible electronic systems manufactured in continuous roll-to-roll processes.

Challenge

""Manufacturers must balance flexibility, safety and long shelf life within very thin structures.""

The central challenge is maintaining electrochemical reliability as batteries become thinner and more mechanically compliant. A primary battery designed for a 10-year shelf life must keep its seals intact through transportation, storage and product flexing. Flexible substrates also need to resist puncture and prevent internal short circuits even when the finished product is folded or compressed. Lithium-based designs require transport and safety certifications such as UN 38.3 and UL 1642 in many applications, adding qualification steps before commercialization. Current thin Li-MnO2 products operate at approximately 3.0 V and may contain less than 0.2 g of lithium metal in compact formats, but safe packaging remains essential. Manufacturers that can validate electrical performance after repeated bending, humidity exposure and temperature cycling will have a significant competitive advantage.

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Segmentation Analysis

By Types

Li-MnO2 Batteries: Li-MnO2 Batteries are estimated to account for approximately 54% of global Primary Flexible Battery Market demand in 2026, making them the leading product type. Their principal advantages are a nominal output around 3.0 V, flat discharge behavior, high energy density and long storage stability. Current thin-cell families provide approximately 400 Wh/kg gravimetric energy density and around 500 Wh/l volumetric energy density. Commercial capacities range from roughly 115 mAh in compact products to 1,600 mAh in larger thin formats. Selected cells can deliver continuous current around 75 mA and pulse current up to approximately 300 mA, supporting RF transmitters and connected electronics. Operating ranges commonly extend from -20°C to 60°C. Through 2035, Li-MnO2 should remain the preferred chemistry for smart cards, medical devices and tracking systems requiring both thin construction and relatively high energy.

Carbon Zinc Batteries: Carbon Zinc Batteries are estimated to represent approximately 28% of global demand in 2026. Printed zinc-manganese dioxide architectures are especially attractive because they can be manufactured using roll-to-roll screen printing and lamination. Individual flexible cells typically provide around 1.5 V, while multiple cells can be connected in series when higher voltage is required. Printed designs can be customized across areas ranging from approximately 1 cm² to 100 cm² with specific capacities around 4 mAh/cm². Current capability generally ranges from approximately 0.1 mA/cm² to 2.0 mA/cm² depending on cell structure. These characteristics make Carbon Zinc Batteries suitable for Novelty Packaging, simple sensors and disposable labels requiring short-duration or low-current operation. Their lower cost and print compatibility should preserve a substantial market position through 2035.

Lithium-ion Batteries: Lithium-ion Batteries are estimated to account for approximately 18% of global Primary Flexible Battery Market demand in 2026. Although conventional lithium-ion technology is usually associated with rechargeable products, thin lithium-based formats continue to influence flexible-battery design where high energy and compact geometry are critical. This category is used in specialized flexible electronic systems requiring higher power density and conformable packaging. Product developers increasingly use pouch structures only a few millimeters thick and integrate protective circuitry where required. The segment remains smaller than Li-MnO2 Batteries because the primary flexible market prioritizes long shelf life and one-time use in many applications. Through 2035, Lithium-ion Batteries should grow selectively in products demanding stronger pulse performance or more advanced electronics than low-current printed cells can support.

By Applications

Smart Security and Payment Cards: Smart Security and Payment Cards are estimated to account for approximately 34% of global Primary Flexible Battery Market demand in 2026, making them the leading application. Powered cards can support authentication, visual displays, one-time passwords, tracking or enhanced wireless communication while retaining a profile compatible with wallets and card readers. Thin battery formats are essential because the full card construction must remain only a few millimeters thick. Li-MnO2 Batteries are particularly attractive because nominal 3.0 V output can power microcontrollers and wireless electronics directly or with minimal conversion. Shelf life exceeding 10 years in selected cells also supports security products that may remain unused for extended periods. Through 2035, smart identity and payment systems should remain a major source of flexible battery demand.

Novelty Packaging: Novelty Packaging is estimated to represent approximately 27% of global demand in 2026. Brands increasingly use illuminated graphics, sound modules, digital indicators and connected packaging to differentiate products and engage consumers. Flexible batteries enable these functions without adding a bulky cylindrical cell. Carbon Zinc Batteries are particularly suitable for simple low-current functions and can be printed with customized dimensions from approximately 1 cm² to 100 cm². Li-MnO2 Batteries are used when wireless transmission or longer operating life requires more energy. A flexible battery integrated into a package can remain dormant for months and activate only when a user opens, presses or scans the product. Digital packaging campaigns should support continued adoption through 2035.

Medical Label: Medical Label applications are estimated to account for approximately 24% of global demand in 2026. Smart medical labels can support temperature monitoring, adherence reminders, diagnostic sensing, drug delivery systems and connected medical records. Thin batteries are valuable because labels need to remain lightweight and unobtrusive while operating for days, months or even years depending on use. Current Li-MnO2 thin cells are already positioned for medical devices and drug-delivery applications and can maintain low self-discharge below approximately 1% after 1 year at room temperature. Operating ranges around -20°C to 60°C support many transport and use conditions. Medical Label should be one of the fastest-growing applications through 2035 as healthcare increasingly adopts disposable connected electronics.

Others: Others are estimated to account for approximately 15% of global demand in 2026. These applications include thin connected products outside Smart Security and Payment Cards, Novelty Packaging and Medical Label where conventional batteries are too bulky. Devices may require only a few milliamp-hours for short-term sensing or more than 1,000 mAh for longer operation. Flexible battery suppliers therefore offer multiple formats and chemistries rather than one universal design. Current thin-cell portfolios can include more than 8 pre-engineered sizes, helping developers avoid completely custom tooling. Through 2035, expansion of smart tags, disposable electronics and low-profile sensors should support gradual growth in this diversified application group.

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Regional Outlook

North America:

North America is estimated to account for approximately 31% of global Primary Flexible Battery Market demand in 2026, making it the leading region. The United States supports strong markets for connected healthcare, secure identification, asset tracking, RFID and intelligent packaging. Supplied companies including Ultralife, Blue Spark Technology and Brightvolt provide regional technology depth across thin primary battery concepts. Current commercial Li-MnO2 thin cells offer capacities from approximately 115 mAh to 1,600 mAh and nominal output around 3.0 V. Security-card and medical applications are especially attractive because thin-cell products can combine long shelf life with comparatively high pulse output.

The North American market is projected to expand at approximately 5.8% annually through 2035. Connected medical products should provide significant incremental demand as more disposable sensors and labels require embedded power. Asset tracking also creates opportunities because RF transmitters need high pulse current even when average energy consumption is low. Current thin Li-MnO2 technology can provide pulse output approaching 300 mA in selected designs. Manufacturers should increasingly offer custom tab geometries and flexible package dimensions so customers can integrate batteries directly into printed circuits and laminated products. Long-term support for safety certification will remain an important competitive factor.

Europe:

Europe is estimated to represent approximately 27% of global demand in 2026. Finland, Germany, France, the United Kingdom and Nordic countries support strong printed-electronics, smart packaging, medical-device and identification technology ecosystems. Enfucell Oy has historically contributed significantly to printed Carbon Zinc Batteries through roll-to-roll screen-printing and lamination concepts. Such printed batteries can provide approximately 1.5 V per cell and be connected in series for higher voltage. Cell areas ranging from 1 cm² to 100 cm² allow designers to adapt power sources to labels and packaging rather than redesigning products around standard battery shapes.

The European market is projected to grow at approximately 5.4% annually through 2035. Sustainability and material efficiency should play a larger role as customers evaluate battery chemistry alongside packaging recyclability. Smart Security and Payment Cards will remain important, while medical labels and intelligent packaging create new opportunities. Printed electronics manufacturing is particularly attractive because batteries, antennas and conductive traces can potentially be produced using compatible roll-to-roll processes. Suppliers that reduce the number of assembly steps by 2 or more operations should gain an advantage in high-volume disposable products.

Asia-Pacific:

Asia-Pacific is estimated to account for approximately 30% of global demand in 2026. China, Japan, South Korea, Taiwan and Southeast Asia combine large electronics, smart-card, packaging and medical-device manufacturing ecosystems. High-volume production is especially important because flexible batteries become significantly more economical when manufactured through automated lamination or roll-to-roll processes. Regional manufacturers can integrate power sources close to card, sensor and label assembly lines, reducing logistics complexity. Li-MnO2 Batteries should remain important for higher-energy products, while Carbon Zinc Batteries serve low-cost printed applications.

Asia-Pacific is projected to be the fastest-growing region at approximately 7.2% annually through 2035. China should remain central to flexible electronics manufacturing, while Japan and South Korea contribute advanced materials and precision packaging. Smart packaging and connected labels should expand as consumer brands use more electronic features. High-volume manufacturing also creates opportunities to reduce battery thickness toward approximately 1 mm while preserving production consistency. Suppliers capable of producing millions of identical flexible cells with automated quality control should gain market share as regional electronics programs scale.

Latin America:

Latin America is estimated to account for approximately 7% of global demand in 2026. Brazil and Mexico represent the largest regional opportunities through smart cards, pharmaceutical packaging, consumer goods and industrial tracking. Flexible batteries remain a relatively specialized product, but growing use of RFID and connected packaging is expanding awareness. Low-cost Carbon Zinc Batteries are particularly relevant where devices require only short operating periods. A printed cell providing approximately 1.5 V can support basic indicators and simple low-power electronics without significantly increasing package thickness.

The region is projected to expand at approximately 6.1% annually through 2035. Mexico should benefit from electronics and medical-device manufacturing, while Brazil provides opportunities across payments, consumer packaging and healthcare. Imported high-performance Li-MnO2 products will remain important for demanding applications, while local converting and packaging companies may increasingly integrate printed battery modules. Cost sensitivity should favor standardized formats rather than highly customized batteries during early adoption. Distribution partnerships with card and label manufacturers should help accelerate market penetration.

Middle East & Africa:

Middle East & Africa is estimated to represent approximately 5% of global demand in 2026. Gulf markets support growing use of smart identification, secure cards, medical technologies and premium connected packaging, while African markets provide longer-term opportunities in payments, healthcare and tracking. Primary flexible batteries are especially useful where devices need long shelf life and cannot be regularly charged. Li-MnO2 technology with more than 98% capacity retention after 1 year at room temperature can support such applications.

The region is projected to grow at approximately 6.5% annually through 2035. Smart payment systems and connected healthcare should provide the largest incremental opportunities. Thin batteries integrated directly into identification or medical products can reduce dependence on replaceable coin cells and improve device form factors. Temperature ranges around -20°C to 60°C are adequate for many indoor and logistics applications, although extreme outdoor environments may require additional thermal protection. Suppliers offering certified products and local integration support should be best positioned for regional growth.

List of Top Primary Flexible Battery Companies

• Enfucell Oy
• Ultralife
• Blue Spark Technology
• Brightvolt

Top 2 Companies Market Share

Ultralife: Ultralife is estimated to account for approximately 21.6% of organized global Primary Flexible Battery Market demand in 2026. Its competitive position is supported by a broad Thin Cell portfolio based on Li-MnO2 chemistry. Current products span more than 8 pre-engineered sizes with nominal voltage around 3.0 V and capacities ranging from approximately 115 mAh to 1,600 mAh. Energy density is around 400 Wh/kg and 500 Wh/l in selected thin-cell formats, while shelf life can exceed 10 years. Operating temperatures generally extend from approximately -20°C to 60°C. The company's products address smart security cards, asset tracking, RFID, medical devices and drug-delivery systems, giving it broad exposure across key applications.

Enfucell Oy: Enfucell Oy is estimated to hold approximately 18.4% of organized global demand in 2026. Its competitive position is associated with printed SoftBattery technology based on zinc-manganese dioxide chemistry and roll-to-roll screen-printing and lamination processes. Individual cells provide approximately 1.5 V and can be connected in series to create higher-voltage formats. Cell areas can be customized from around 1 cm² to 100 cm², with specific capacity near 4 mAh/cm² and current capability of approximately 0.1-2.0 mA/cm² depending on internal architecture. This manufacturing flexibility is particularly valuable for Novelty Packaging, labels and other low-current applications where battery geometry must conform to the final product.

Investment Analysis

Investment in the Primary Flexible Battery Market is increasingly focused on thin Li-MnO2 pouch construction, roll-to-roll Carbon Zinc manufacturing, moisture-resistant packaging and automated electrical testing. The market's 5.7% CAGR creates steady expansion opportunities, but competitive value increasingly depends on manufacturing repeatability rather than basic chemistry alone. Li-MnO2 Batteries account for approximately 54% of 2026 demand and provide the strongest premium opportunity because energy density can reach around 400 Wh/kg. Printed Carbon Zinc Batteries remain attractive for ultra-low-cost products where cell area can be customized from roughly 1 cm² to 100 cm². Automated lamination and printing should reduce unit cost as production volumes increase. Investment in flexible sealing materials is equally important because multi-year shelf life depends on protecting thin electrodes from moisture and mechanical damage.

Asia-Pacific provides the strongest growth-oriented investment opportunity because it accounts for approximately 30% of 2026 demand and is projected to expand around 7.2% annually through 2035. North America remains attractive for medical and secure-card applications, while Europe provides expertise in printed electronics and roll-to-roll production. Investors should also consider the growing importance of certification and qualification. Li-MnO2 products used in medical or transportation applications may require UN 38.3, UL 1642 and IEC 60086-4 compliance, adding technical barriers that favor experienced manufacturers. Suppliers capable of supporting more than 8 standardized cell sizes alongside custom configurations can address both low-volume prototyping and high-volume production programs. Integration partnerships with label, card and packaging converters should become increasingly important.

New Product Development

New product development is increasingly centered on thinner, higher-energy Li-MnO2 formats that can replace conventional coin cells. Current Ultralife Thin Cell products provide approximately 3.0 V output and cover capacities from around 115 mAh to 1,600 mAh. Energy density around 400 Wh/kg and 500 Wh/l allows devices to achieve slimmer profiles than equivalent coin-cell architectures. Selected compact cells weigh only around 1.1 grams, while larger versions remain below approximately 15 grams. The technology also offers low self-discharge below 1% after 1 year at 20°C and shelf life exceeding 10 years. Through 2035, development should focus on reducing thickness toward approximately 1 mm while maintaining pulse capability, sealing reliability and compatibility with automated electronics assembly.

Printed battery development is also progressing toward broader shape customization and direct integration with flexible circuits. Zinc-manganese dioxide systems can be produced using screen printing and lamination with specific capacity around 4 mAh/cm². Designers can create battery areas between approximately 1 cm² and 100 cm² and connect multiple 1.5 V cells in series to achieve application-specific voltage. Conductive carbon, copper or silver contact pads can be integrated according to assembly method, while clamp, conductive tape and conductive ink connections support different packaging structures. These characteristics make printed batteries particularly attractive for Novelty Packaging and Medical Label products. Future development should increasingly combine power generation, printed antennas and sensors within one laminated module, reducing total assembly thickness and component count.

Five Recent Developments

• November 2025: Ultralife refreshed technical documentation for multiple Thin Cell products, expanding standardized engineering data across more than 8 compact primary battery formats for connected and embedded electronics.
• December 2025: Ultralife updated Thin Cell specifications highlighting 3.0 V Li-MnO2 designs with energy density around 400 Wh/kg and shelf life exceeding 10 years in selected products.
• September 2025: Primary flexible battery development increasingly emphasized security cards, RFID, asset tracking and medical devices using compact Li-MnO2 cells with operating ranges from approximately -20°C to 60°C.
• June 2025: Printed flexible-battery programs continued advancing roll-to-roll zinc-manganese dioxide architectures offering cell areas from approximately 1 cm² to 100 cm² for customized labels and packaging.
• October 2024: Flexible power developers expanded low-profile printed battery integration with conductive tape and conductive-ink connections, supporting more direct assembly into smart packaging and disposable electronic products.

Report Coverage

The Primary Flexible Battery Market analysis covers development from 2025 through 2035, incorporating the transition from USD 452.3 million in 2025 to USD 478.08 million in 2026 and the projected USD 783.15 million level by 2035 at a 5.7% CAGR. Product coverage is limited to Li-MnO2 Batteries, Carbon Zinc Batteries and Lithium-ion Batteries, estimated at approximately 54%, 28% and 18% of 2026 demand respectively. Application coverage includes Smart Security and Payment Cards at approximately 34%, Novelty Packaging at 27%, Medical Label at 24% and Others at 15%. The assessment evaluates thin pouch cells, printed batteries, 1.5 V and 3.0 V architectures, roll-to-roll manufacturing, pulse performance, shelf life, flexible packaging, energy density, RFID power and disposable connected electronics.

Regional coverage includes North America at approximately 31% of 2026 demand, Asia-Pacific at 30%, Europe at 27%, Latin America at 7% and Middle East & Africa at 5%. Competitive coverage includes Enfucell Oy, Ultralife, Blue Spark Technology and Brightvolt. The report evaluates thin-cell capacities from approximately 115 mAh to 1,600 mAh, energy density around 400 Wh/kg and 500 Wh/l, shelf life above 10 years, self-discharge below 1% after 1 year, pulse output up to approximately 300 mA, printed cell areas from 1 cm² to 100 cm², specific capacity near 4 mAh/cm² and operating temperatures around -20°C to 60°C. It also examines smart cards, connected packaging, medical labels, RFID and the transition toward increasingly thin integrated primary power through 2035.