Week 39 at BatteryDesign.net

Jerry Wan's post (right) asks whether cell design has a "golden ratio" for aspect ratio. He concludes that there isn't a universal one, and that's right.

The Mobile Power Plant Ultra 2.0 puts up to 2,036 kWh of CATL battery packs, a converter, EV charging outlets and a solar inverter into a standard 20-foot container.

Week 37 Roundup of BatteryDesign.net

Lamination bonds the separator directly to both electrode faces using heat and pressure to soften a thin adhesive coating already on the separator before the electrode stack is built.

BatteryDesign.net latest from 4th September

Over the past 25 years, battery technology has improved dramatically, yet battery startups have struggled. At Catalus Capital, we have unique and extensive insight into the industry, resulting in an i...

Maintaining adequate overlap, whereby the anode active area overlaps the cathode, is critical to achieving uniform current distribution and consistent electrochemical performance.

CATL's automotive-grade NMC811 prismatic cell ships with a headline safety feature: a "Dual Vent Safety Design."

Underneath that, five engineering problems are being fought at once, and each one constrains the others: what the electrodes are made of, how fast heat can be pulled out of a space the size of a credi...

While silicon (SiOx/SiC/Si) based anodes skyrocket battery capacity, their swelling character reaching up to 300% volume expansion transforms cell design from a purely electrochemical challenge into a...

Somewhere in your house is a drawer full of dead phones, old laptop chargers, and a cable for a device you no longer own.

A pack charging time estimator built using the Electric Vehicle packs in the Battery Pack Database.

4th generation LFP is the point at which this became a genuinely high-precision, high-barrier-to-entry manufacturing problem rather than a simple powder upgrade.

Failure Mode and Effects Analysis (FMEA) is a structured method for identifying how a component, process, or system can fail, what happens when it does, and how likely that failure is to reach a custo...

Lithium-ion batteries power modern life, from the phone in your pocket to the electric vehicle in your driveway to the grid-scale energy storage facility humming at the edge of town.

It's really interesting to look at cell chemistry and format vs application as there is nothing really stopping us from applying any chemistry or cell format to any application.

It is useful to look at an idealised Nyquist Plot of a lithium ion battery. Starting with a detailed, feature-by-feature description of the idealised Electrochemical Impedance Spectroscopy (EIS) Nyqui...

Led by Dr. Galo J. Páez Fajardo and Professor Louis F. J. Piper, the paper addresses a fundamental question in battery science: how exactly do lithium-ion battery cathodes store and release energy at ...

A simple creepage and clearance calculator, providing indicative minimum distances based on IEC 60664-1:2020 and ISO 21498:2021 table lookups with linear interpolation.

We have already looked at the BMW iX3 Neue Klasse Battery and the BMW Gen6 EV Battery Technology behind it. The second Neue Klasse model, the BMW i3 (badged NA0, reviving the i3 name for an all-electr...

A practical reference for sub-milliohm resistance testing in battery pack hardware: cell tab welds, busbar joints, contactor and relay contacts, and BMS current shunts.

The exact number of temperature sensors you need depends on the size of your battery pack, its physical configuration, rate of charge/discharge (C-rate), and the required level of thermal observabilit...

Download the battery pack database and tools for calculating pack performance

the quantity of liquid electrolyte has to be very carefully controlled in such high-energy cells to avoid 'Electrolyte Motion Induced Salt Inhomogeneity' (EMSI)

The State of Certified Energy (SOCE) means the measured or on-board usable battery energy at a specific point in its lifetime, expressed as a percentage of the certified usable battery energy. This co...

There are many different pieces of legislation, rules and regulations around battery design. By country, application and field.

With the Toyota Prius they have perhaps one of the longest and best names in hybrid vehicles, Toyota Batteries have a good reputation.

There are many different pieces of legislation, rules and regulations around battery design. By country, application and field.

What the Announcement Means for Battery Engineers At the 2026 Powering the Nation Forum, Wu Kai — Chief Scientist at CATL and an academician of the Chinese Academy of Engineering — made the most signi...

We are gradually adding a number of electric vehicle and battery calculators to our pages. Here is a centralised list of pages with calculators built into them.

Choosing between aluminium and copper is one of the first decisions in any busbar design. Both materials are capable conductors, but they make very different engineering trade-offs.

Battery energy storage systems are specified differently from EV packs. The load profile, cycle regime, and contractual performance requirements all feed into the sizing process — and getting any one ...

BatteryDesign.net is the engineering reference for battery designers. Free cell and pack benchmarking data, the Battery A to Z, calculators, and in-depth technical content from chemistry to system integration. Written by engineers, for engineers.

Recent study by Speira outlines potential benefits of an aluminium cell housing based on a 4680 concept cell.

Battery Pack Sizing: In simple terms this will be based on the energy and power demands of the application.

Battery engineering draws from more disciplines than almost any other field in engineering. A complete battery system requires electrochemistry, thermal engineering, power electronics, embedded softwa...

If you've spent your career in mechanical engineering, power electronics, software, automotive systems, or aerospace — and you're now working on batteries — you're in the right place.

Abbreviated as LMO and sometimes written as Li-manganese or lithium manganate. LMO is a lithium-ion cathode material that uses manganese as the transition metal rather than cobalt or nickel.

As the primary intelligence layer within a high-voltage battery pack, the BMS is tasked with ensuring the safety, longevity, and performance of electrochemical cells that are increasingly being pushed...

The cost of producing a digital battery passport is not a single, flat fee but rather a comprehensive, phased investment that encompasses software platforms, physical marking, compliance audits, and l...

The total lifetime emissions of a battery is dependent on the emissions generated in making it and how long it lasts, hence "Carbon Footprint is a 2-axis Problem".

Desay Battery officially unveiled its latest breakthroughs under the theme: “Expanding Sodium-ion Boundaries, Empowering with Semi-Solid Technology.”

In yet another breakthrough Nuvvon has used its Solid Polymer Electrolyte (SPE) to combine a high silicon anode with a high nickel cathode. See below data set for 1Ah 40% silicon graphite vs NMC 811.

The sodium-ion supply chain: what the chemistry doesn’t tell you