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 ↓

BMS Software Control and Signal Flow Architecture
Most explanations of a battery management system, including our own BMS overview, describe it stage by stage: here’s how coulomb counting works, here’s how a contactor gets driven, here’s what isolation resistance means This is useful, but it leaves out what engineers … Read more
Magnesium as a Battery Enclosure Material
Where the benchmark report asks how Estes Energy Magnus compares numerically to other packs, this one asks a narrower question: is magnesium actually the right enclosure material, on the physics and the evidence published so far. Magnus is used throughout as the … Read more
Magnus (Estes Energy) Pack Benchmark
“What are the benefits of a Magnesium battery pack enclosure?” arrived in my inbox with a link to the Estes Energy website. That got me looking at this particular design as a benchmark and also more generally about the use of magnesium … Read more
CATL’s “Dual Vent” Prismatic Cell
CATL’s automotive-grade NMC811 prismatic cell ships with a headline safety feature: a “Dual Vent Safety Design.” The specifications: We believe this cell is for ACC. Jerry Wan shared details of this CATL cell on LinkedIn and it got us thinking: Why vent … Read more

→ list all new posts

Write for BatteryDesign.net

BatteryDesign.net welcomes contributions from engineers, researchers, and specialists across the battery field. If you have expertise in an area the site doesn’t yet cover well — or a perspective worth sharing — get in touch.

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

Stay Current

The newsletter covers new posts, new benchmarking data, and notable developments in battery engineering — roughly every two weeks. Free. No marketing. Same tone as the site.

Already a subscriber? The welcome email with all the key links is here.

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

More Tools →

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.

Download for $5 →