Costs

Cell Size & Format Selection Heavily Impacts Battery Pack Costs

Bigger cells result in lower pack cost on a $/kWh basis Scaling cell size increases the volume of active materials in the pack while reducing passive components (e.g. casings, housings, thermal interface materials), resulting in higher pack-level energy density and lower $/kWh.

However, cells account for 70% of overall pack cost, and cell format selection still matters:

Prismatic (especially large ‘Bladeʼ cells) give the best volumetric utilisation and can be load-bearing, reducing structural components.

Pouch: typically need multiple smaller modules and additional housing to maintain compression.

Cylindrical: geometry limits volume utilisation compared to prismatic. Therefore, large prismatic cells deliver the lowest overall pack costs.

Source: Content & analysis provided by CRU Group Distinguished Partner). For more information, visit crugroup.com

Extracted from the PDF; charts and images may read imperfectly.