The engineering reference for battery designers

From cell chemistry to pack integration — technical depth for engineers who are serious about batteries.

New to batteries? If you’ve come from mechanical, software, power electronics, or aerospace and you’re now working on batteries, start here. → Your discipline-specific onramp

Need a specific answer? The A to Z lists every core page and topic alphabetically. If you can’t find something through the navigation, the A to Z will have it. → Browse the A to Z

Want the data? The cell and pack databases are downloadable Excel files. Over 1,550 cells and >1800 production packs. → Downloads

Chemistry

The electrochemical foundation — LFP, NMC, NCA, NCMA, sodium-ion, solid state, and what the trade-offs actually mean for pack design. → Explore chemistry

Module

Cell grouping, interconnects, compression, thermal management, and the C2P transition — what the module layer gives you and what it costs. → Explore modules

BMS

SoC, SoH, cell balancing, contactor control, harness design, functional safety, and cloud analytics — from algorithm to ASIL D. → Explore the BMS

Safety

Thermal runaway, propagation, functional safety, EUCAR hazard levels, abuse testing, and HV safety. → Explore safety

Battery Cell

Formats, design, testing, manufacturing, and benchmarking. Everything from coin cell to 4680, with real production data throughout. → Explore the cell

Battery Pack

Pack architecture, sizing, enclosure design, 400V vs 800V, and real benchmarking data from production vehicles and BESS. → Explore pack design

Thermal

Heat generation, cooling architectures, TIM selection, battery heating, and thermal runaway containment. → Explore thermal management

Charging

CC-CV, fast charging, EV connectors and standards, ISO 15118, V2G, and how charging strategy affects pack lifetime. → Explore charging

What’s new ↓

Compression Pad Selection
How to select a battery compression pad: start from the BOL and EOL pressure window, size thickness for cell growth, and compare PU, silicone and EVA on compression set, stress relaxation and temperature.
Batteries for AI Data Centres: BBU vs UPS
An AI training rack is not a bigger version of an old server rack. It draws power in a different pattern, at a different voltage, and the battery that protects it has moved from a separate battery room to a shelf inches … Read more
Mercedes CLA EV Battery: 85 kWh and 58 kWh Pack Analysis
Pack analysis of the production Mercedes CLA: 58 kWh LFP, 71 kWh and 85 kWh NMC packs from CATL, 192 cells at 800V, charging curve, and comparison with Tesla Model 3 and BMW Neue Klasse.
Field-Aged Kona Packs Torn Down: Capacity vs Resistance (Fischer et al. 2026)
A review of Fischer et al. (2026): three 5 to 6 year old Hyundai Kona Electric packs measured intact and then component by component, showing how capacity and ohmic resistance scale from cell to pack.

→ list all new posts

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Posts are accepted from individuals, academics, institutions, manufacturers, and consultancies. The only requirement is technical accuracy and genuine usefulness to practising engineers.

Contact: nigel@batterydesign.net → LinkedIn

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BatteryDesign.net is built and maintained by Nigel Taylor — 30 years in automotive engineering, 14 years in electrification and battery design, based in the UK. → About

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The Battery A to Z PDF – 130+ pages covering 400+ terms with definitions, diagrams, and examples. The reference document you’ll keep open alongside whatever you’re working on.

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