In the past, a long-term client messaged me asking if our new batch of TWS prototypes could be "upgraded to Bluetooth 5.4." When I asked why, he paused for a second and said, "Well, isn't 5.4 the standard now?"
This conversation is quite telling. The Bluetooth 5.4 specification was actually released by the Bluetooth Special Interest Group in early 2023. Three years later, many B2B buyers still view it merely as a "newer version number."
Is it truly worth implementing in new projects? And what does it actually mean for OEM orders? Let’s dive in.
Don't Rush to Upgrade: What 5.4 Actually Changed
The core of Bluetooth 5.4 boils down to two acronyms: PAwR and EAD.
PAwR stands for "Periodic Advertising with Responses." To use an analogy—older Bluetooth broadcasting was like a mall PA system; it only shouted one-way announcements, and no one could talk back. PAwR turns that megaphone into a walkie-talkie.
A central device can now communicate bi-directionally with thousands of terminals simultaneously while staying incredibly energy-efficient. While originally designed for Electronic Shelf Labels , this low-power two-way communication logic is now trickling back into the earbud industry. Silicon Labs
EAD (Encrypted Advertising Data) is even easier to grasp. Simply put, older Bluetooth advertising packets were like "postcards" ，anyone passing by could take a peek. EAD turns them into encrypted envelopes. Only devices that have "exchanged the secret code" have the right to open and read them. For earbuds, this acts like a privacy screen during the pairing process, significantly reducing the risk of data exposure.
What Do TWS Users Actually Feel?
Technical specs are cold, but user experience is personal. You might ask: can someone wearing earbuds actually tell the difference?
Stability is the most direct benefit. You'll notice it most when switching between a phone, laptop, and tablet. The 5.4 broadcasting mechanism noticeably improves reconnection speed and link stability. Power consumption has also slightly dropped. With the same battery capacity, you might get an extra 30–40 minutes of playtime,a tangible difference for compact TWS products.
However, there’s a catch: Bluetooth 5.4 itself doesn't equal a leap in audio quality. The real game-changer for sound and latency is the combination of LE Audio and the LC3 codec. If you just swap in a 5.4 module without running LE Audio, the user won't perceive most of these upgrades. This is a point we constantly clarify with our clients during project consultations.
Three Real Impacts on the OEM Manufacturing Side
From a factory perspective, the changes are even more practical.
1. The Shift in Chipset Selection
Mainstream Bluetooth audio chip vendors like BES, Airoha, and Jerry are now making 5.4 the default in their new solutions. In fact, choosing an older 5.3 SKU now often requires extra inventory checks with the original manufacturer. This means for new projects, 5.4 is no longer an "add-on" but the "standard."
2. BOM Costs Have Flattened
Before 2024, moving to 5.4 meant paying a premium. Today, the price gap in mass-production solutions has shrunk to almost zero. For high-volume clients, this is great news: you don't have to pay extra just for a modern spec.
3. More Granular Client Communication
In the past, buyers just asked, "In the past, buyers just asked, ") Now, more B2B clients are asking specific questions like, "Does it support LE Audio broadcasting?" or "Is it Auracast-ready?" This is a positive trend—tech-savvy clients push us to refine our factory's solution capabilities.
The Verdict: Should You Switch?
If your new project is scheduled for 2026, I suggest making Bluetooth 5.4 your default. There's no reason to look back. Whether you should also enable LE Audio or Auracast depends on your target market and price point—we usually recommend it for high-end Western markets, while for high-volume entry-level markets, focusing on basic connection stability and battery life is more practical.
At the end of the day, a version number is just a line on a spec sheet. Real competitiveness comes from the entire chain—from chipset selection and antenna tuning to mass-production consistency.
If you are planning your next generation of OEM earbuds and want to discuss specific Bluetooth solutions or chipset options, feel free to reach out to our project lead, caitlin@sonun.com. We can provide tailored advice based on your target market and order volume.
