Modular Robotics Recalls Rechargeable Battery Packs Due to Burn Hazard

What was recalled

In April of 2020, the U.S. Consumer Product Safety Commission (CPSC) announced a significant recall involving rechargeable battery packs manufactured by Modular Robotics. This action was taken after the company identified a potential safety defect in these specific power units that could lead to overheating. The recall focuses on a particular type of NiMH (Nickel-Metal Hydride) battery pack that was marketed primarily for use in educational robotics kits. While Modular Robotics is the brand name associated with the recall, you may also see the product labeled under "Dexter Industries," as this is the name printed clearly on the white label affixed to the battery packs themselves. Understanding exactly which items are affected is crucial, as these batteries were not sold exclusively as standalone products but were often bundled within larger educational kits.

The specific item at the center of this recall is a 9.6-volt, 2000mAh NiMH rechargeable battery pack. It is important to note the distinction between the brand name on the box and the label on the device; while Modular Robotics manufactured it, the white label attached to the unit reads "Dexter Industries Rechargeable Battery Pack." Visually, you can identify this recalled item by its black plastic wrapping, which encases the battery cells. The technical specifications printed on the label indicate a maximum charge current of 2A. If you have one of these packs, it was sold both individually and as part of several popular robotic learning bundles. Specifically, these batteries were included in Classroom Kits, GoPiGo robotic kits, and BrickPi robotic bundles. If you purchased any of these educational robotics sets between the relevant timeframes leading up to April 30, 2020, there is a chance your kit contains one of these affected battery packs.

The scope of this recall is defined by the physical characteristics of the battery rather than just the serial number. Because these batteries were integrated into various kits and sold separately, consumers need to inspect the actual power source in their possession. The recall does not cover all Modular Robotics products, only those containing this specific 9.6V NiMH unit wrapped in black plastic with the Dexter Industries label. It is a targeted recall based on a manufacturing flaw in this particular component, rather than a broad product line issue. By identifying the exact model and labeling, consumers can determine whether their equipment falls under the safety notice without unnecessary confusion or alarm.

The hazard, explained

At the heart of this recall is a specific failure mode involving the rechargeable battery packs used in Modular Robotics products. These are 9.6V 2000Ah NiMH (Nickel-Metal Hydride) units wrapped in black plastic, clearly labeled with "Dexter Industries Rechargeable Battery Pack" on a white sticker. While NiMH batteries are generally reliable and widely used in robotics kits like the GoPiGo and BrickPi, they are not immune to internal defects. In this instance, the manufacturer has identified that certain packs can experience an internal short circuit. To understand why this is dangerous, it helps to look at what happens inside a battery when that seal or separator fails.

A rechargeable battery works by moving lithium or metal-hydride ions between two electrodes through an electrolyte. When a short circuit occurs, the electrical current bypasses its intended path and flows directly across the internal components with little to no resistance. This causes the electrical energy to convert rapidly into thermal energy—heat. Because the battery is enclosed in tight black plastic wrapping, that heat cannot dissipate quickly. The temperature inside the pack can spike dramatically in a very short period, leading to the overheating reported by consumers.

The physical evidence of this failure is alarming but clear: Modular Robotics has received four reports of these specific battery packs smoking. Smoking is a critical warning sign in battery chemistry. It indicates that internal materials are breaking down due to excessive heat, potentially releasing gases or vaporized electrolytes. If left unchecked or if the short circuit worsens, this thermal runaway can lead to melting, leakage, or in severe cases, fire. Even without reaching the point of ignition, the surface temperature of the pack can become hot enough to cause immediate burns to the skin upon contact.

This is particularly relevant for users who handle these components frequently. The recall notes that no injuries have been reported so far, which is fortunate, but the risk remains real. A burn from an overheating battery is not just a minor irritation; it can cause first or second-degree burns depending on how long the skin is in contact with the hot surface. Since these packs are often used in educational settings where students might be handling them for extended periods during robotics projects, the potential for accidental contact with a hot casing is significant. The hazard is not just about the battery stopping work; it is about the device becoming a source of physical injury due to uncontrolled heat generation.

Understanding this mechanism underscores why stopping use immediately is the only safe course of action. You cannot "cool off" a short-circuited battery and expect it to remain safe. The internal damage that caused the short is likely permanent, meaning the risk of further overheating persists until the unit is removed from service and disposed of properly according to local hazardous waste laws.

Who is most at risk

The primary group affected by this recall consists of educators, students, hobbyists, and parents who utilize Modular Robotics’ educational kits. Specifically, the individuals at risk are those who own or have used the 9.6V 2000Ah NiMH rechargeable battery packs that were sold either as standalone units or bundled with Classroom Kits, GoPiGo, and BrickPi robotic systems. Because these products are designed for learning environments and personal projects, the users range from young children in elementary classrooms to teenagers and adults engaging in STEM (Science, Technology, Engineering, and Mathematics) activities at home.

While any user handling a defective battery pack faces the potential for a burn hazard due to overheating or short-circuiting, certain demographics may be more vulnerable depending on how they interact with these devices. Children and younger students, who are often the primary users of GoPiGo and Classroom Kits, may lack the immediate situational awareness needed to recognize the early signs of battery failure. If a pack begins to smoke or become excessively hot during use, a child might not immediately understand the danger or know how to safely disconnect the power source. This delay in response can increase the likelihood of skin contact with a hot surface, leading to burns.

Educators and parents supervising these activities also bear a significant responsibility for safety. In a classroom setting with multiple students working simultaneously on robotic projects, a single overheating battery pack could cause confusion or panic if not handled correctly. The risk is compounded by the fact that these battery packs are wrapped in black plastic, which can make it difficult to visually detect early signs of swelling or damage until the issue becomes severe. Furthermore, because the defect involves short circuits leading to overheating, the heat generated may not be immediately apparent to the touch if the user is wearing gloves or is focused intently on programming or assembling the robot.

It is important to note that while no injuries have been reported as of the recall date in April 2020, the potential for harm exists for anyone who continues to use these packs. The risk is not limited to direct contact; overheating batteries can also damage nearby components or ignite flammable materials if left unattended. Therefore, all individuals who possess these specific battery packs—regardless of age or experience level—should be considered at risk until they have taken the necessary steps to replace the defective unit. The vulnerability lies less in the user’s identity and more in their continued exposure to a known defect that can escalate from a minor technical glitch to a physical hazard.

How to tell if you have the recalled item

Before you take any action, the most critical step is to confirm whether your specific battery pack falls under this recall. Because the affected products were sold in various configurations—individually and as part of larger robotic kits—it can be easy to miss the details at a glance. The U.S. Consumer Product Safety Commission (CPSC) has identified a very specific set of physical characteristics that define the defective unit. You need to look for a rechargeable battery pack that is wrapped in black plastic. This outer wrapping is your first visual cue; if your battery is encased in clear or white plastic, it is likely not part of this specific recall lot. However, do not rely on color alone. The definitive identifier is the label.

Please examine the white label printed directly onto the battery pack. You are looking for the text "Dexter Industries Rechargeable Battery Pack." This branding is crucial because Modular Robotics, the manufacturer issuing the recall, operates under or in close association with Dexter Industries. If you do not see this specific name on the white label, your product is not included in this safety notice. Beyond the brand name, you must verify the technical specifications printed on that same label. The recalled items are strictly 9.6V 2000Ah NiMH battery packs with a Max Charge Current of 2A. If your unit has different voltage, capacity, or charge current specifications, it is not the hazardous model being addressed here.

You should also consider how and where you originally purchased this item, as context can help narrow down your search. These specific battery packs were sold individually to hobbyists and educators. They were also bundled inside several popular educational robotics products, including Classroom Kits, GoPiGo bundles, and BrickPi robotic kits. If you bought a complete robot kit rather than just the battery, check the documentation or the packaging insert to see if it lists this specific battery model as an included component. The recall was announced on April 30, 2020, so items purchased significantly after that date may have been replaced with updated, safe inventory, though verifying the physical label remains the only surefire method.

To summarize your inspection checklist: first, find the battery pack used in your robotic device. Second, look for the black plastic wrapping. Third, read the white label to confirm it says "Dexter Industries Rechargeable Battery Pack." Fourth, verify the specs match 9.6V, 2000Ah, NiMH, and a Max Charge Current of 2A. If all these criteria match, you have the recalled product. Please stop using it immediately. Do not attempt to test it or charge it further, as the defect involves internal short circuits that can cause overheating. Once you have confirmed the identity of the item, move on to the remedy steps to get your free replacement safely.

What to do — step by step

Your refund, repair, or replacement options

If you have determined that you possess the recalled Modular Robotics rechargeable battery pack, the good news is that the company has established a straightforward and cost-free remedy to resolve the issue. Because the product poses a direct safety risk due to its potential to short circuit and overheat, Modular Robotics is not asking you to attempt a repair yourself. Instead, they are offering a complete replacement at no charge. This is a standard and responsible approach for hardware defects involving power sources, as attempting to fix a compromised battery internally can be dangerous and is rarely effective. By providing a new unit, the company ensures that your robotic projects can continue safely without the risk of fire or injury.

To initiate this process, you will need to contact Modular Robotics directly. The recall notice specifies that they have set up a toll-free hotline that operates twenty-four hours a day, seven days a week, ensuring you can get assistance regardless of your time zone or when you discover the defect. You can reach their support team at 877-233-6859. When you call, have your product details ready. If you purchased the battery pack individually, or as part of a Classroom Kit, GoPiGo bundle, or BrickPi robotic bundle, having your order information or serial numbers (if applicable) might help speed up the verification process, although the primary identifier is the physical description of the item.

In addition to calling, you may also visit the firm’s official website at www.dexterindustries.com. On the homepage, look for a section labeled "Recall" and click on it. This online portal is designed to provide additional information about the recall and likely offers an alternative way to submit your request or find more detailed instructions if you prefer written communication over phone support. Whether you choose to call or visit the website, the core outcome remains the same: you will receive a free replacement battery pack.

It is important to understand that this remedy does not include a cash refund. The company’s focus is on safety and product integrity, so they are replacing the defective unit rather than returning your money. This means you will need to wait for the new battery to arrive before you can resume full use of your robotics equipment. Please remember to dispose of the old, defective battery pack safely. Do not simply throw it in the regular trash. Follow your local laws and regulations for the disposal of batteries, as these items contain chemicals that can be harmful to the environment if not handled correctly. By following these steps—contacting the company, receiving the free replacement, and disposing of the old unit properly—you ensure your safety and maintain the functionality of your robotic kits.

What can happen if you ignore it

It is completely understandable why you might hesitate to stop using your Modular Robotics battery pack. You may have invested significant time into a robotics project, or perhaps the kit was a gift that sparked a child’s interest in engineering and coding. The inconvenience of pausing your work to handle a recall can feel frustrating, especially when the device appears to be functioning normally on the surface. However, ignoring this recall is not merely an administrative oversight; it is a decision that carries tangible physical risks that extend far beyond the immediate moment of use.

The core issue with these specific rechargeable battery packs lies in their potential to short circuit internally. When a battery shorts, it bypasses its normal safety mechanisms and allows electrical current to flow uncontrollably. This sudden surge generates intense heat very quickly. As noted by the Consumer Product Safety Commission (CPSC) and Modular Robotics, this overheating is not just a minor warmth; it is significant enough to cause burns to consumers who are holding or touching the pack while it charges or operates. The black plastic wrapping that encases the "Dexter Industries Rechargeable Battery Pack" may insulate the heat initially, making it difficult to detect until the temperature rises to dangerous levels.

While Modular Robotics has reported four specific incidents involving these packs smoking and overheating, and no injuries have been confirmed at this time, the absence of reported harm should not be mistaken for safety. Smoke is a critical warning sign that chemical reactions within the battery are becoming unstable. If you continue to use a pack that has already shown signs of thermal instability, or if you ignore the risk entirely, you are gambling with your personal safety and the safety of those around you. A burn from an overheated lithium or NiMH battery can be severe, causing pain, tissue damage, and potentially requiring medical attention.

Furthermore, ignoring the hazard does not make it disappear. The defect remains in the battery’s internal structure. Continued use increases the likelihood that a short circuit will escalate from merely smoking to potentially rupturing or igniting, especially if the pack is left unattended while charging. This risk is heightened in home environments where children or pets might interact with the device. By choosing not to act, you are allowing a known defect to remain active in your workspace, turning a tool for learning and creation into a potential source of physical injury. The inconvenience of swapping out the battery is minor compared to the serious consequences of neglecting a burn hazard.

Staying safe: broader tips

While this specific recall addresses a defect in Modular Robotics battery packs, the incident serves as a valuable reminder about the general safety of all rechargeable energy storage devices, particularly those used in robotics, educational kits, and DIY electronics projects. Lithium-ion and Nickel-Metal Hydride (NiMH) batteries are incredibly convenient, but they store significant chemical energy that must be managed with care. When dealing with any high-capacity battery pack, the first line of defense is proper charging infrastructure. Always use only the charger provided by the manufacturer or one explicitly certified for that specific battery chemistry and voltage. Using a mismatched charger can disrupt the delicate balance of ions within the cell, leading to overheating, swelling, or in worst-case scenarios, thermal runaway—a condition where the battery’s internal temperature rises uncontrollably.

Vigilance during the charging process is equally critical. It is never advisable to leave rechargeable batteries charging unattended for extended periods, such as overnight or while you are away from home. Modern chargers often have automatic shut-off features, but hardware failures can occur. By keeping an eye on your devices during their initial charge cycles, especially if the battery is older or shows signs of wear, you can catch early warning signs like unusual heat, hissing sounds, or a distinct chemical odor. If any of these symptoms appear, disconnect the power source immediately and move the device to a safe, non-flammable area outdoors or in a garage, away from your home.

Storage practices also play a major role in preventing accidents. Never store rechargeable batteries in extreme temperatures, such as inside a hot car during summer or a freezing shed in winter, as this can degrade the internal structure of the cell and increase the risk of leakage or failure. If you are not using your robotic kits for a long period, it is best to store the batteries at a partial charge (around 40-60%) in a cool, dry place. This reduces stress on the battery chemistry compared to storing them fully depleted or fully charged.

Finally, make recall checks a regular part of your home safety routine. Product safety evolves, and manufacturers occasionally discover issues after a product has been sold. Visit www.recalls.gov periodically to search for updates on electronics you own. You can also sign up for email alerts from the Consumer Product Safety Commission (CPSC) to receive immediate notifications about significant recalls affecting your household items. Being proactive about these small details ensures that you enjoy the benefits of modern technology without compromising your family’s safety.