Current fabrication methods for lithium-ion batteries impose a limit on how light a high power battery can be made. The lack of lightweight (< 300 mg), high power batteries is a significant constraint to the development of untethered micro-robots, wearable haptics, mobile computing, and biomedical applications. We have developed a laser micro-machining and assembly process which can produce batteries up to 30 times lighter than the lightest high power commercial cell, at comparable power densities (> 1 kW/kg). Our process is versatile and can be adapted to make custom geometries, miniature high voltage cells, and more, all while using a broad range of starting materials. We see this technology as a path to highly versatile miniature power sources, that will enable a wide range of small-scale applications.Existing fabrication technologies cannot be used to make lightweight, high power density lithium-ion batteries (< 300 mg). The need is increasing for these small, powerful batteries, as advances in fabrication techniques push the limits of miniaturization in robotics, [1] haptics, [2] wearable and biomedical technologies, [3] and mobile computing for the Internet of Things. [4] Unfortunately, current fabrication methods for lithium-ion cells force the end user to make a choice between high energy density and lightweight batteries (Figure 1(a)). Supercapacitors can provide even higher power density (> 10 kW/kg), but have very short discharge times (0.1-5 s), which limits the range of potential applications. [5] To push the limits of performance, we have developed a hybrid manufacturing approach which uses commercially available lithium-ion materials and a laser micro machining method to build lightweight (10-200 mg) high power density (> 1 kW/kg) batteries.Miniaturization of Li-ion batteries is limited by how the fabrication processes scale down, [5,6] Conventional Li-ion electrodes are made as planar films that are stacked into prismatic or cylindrical shapes. The stacked electrodes are infused with electrolyte, then sealed into a metallized film pouch, which prevents moisture from infiltrating into the battery. The materials and processes used to prevent moisture infiltration take up a significant amount of total battery weight, and scale unfavorably as the size of the battery is reduced. Furthermore, most nickel and aluminum commercial tabs weigh hundreds of milligrams, and need large areas for reliable welding to the electrodes. For high power devices, tabs and welds need to be oversized to avoid excessive resistive heating during fast charge or discharge. While several devices have been demonstrated to deliver high power at very small-scale (1-100 mg), the fabrication processes are either long duration, [7] or rely on unconventional materials, [8] or are difficult to replicate. [9] In addition, the most established processes to make lightweight batteries rely on thin-film, solid electrolyte chemistries, which suffer from rate limitations at room temperature, [10,11] To create lighter mesoscale power sources,...