It is really interesting to look at cell chemistry and format vs application, because in principle there is nothing stopping us from applying any chemistry or cell format to any application. In practice, however, the market has converged on some clear preferences. Here we have taken the Battery Pack Database and looked at this question with regards to packs in production.
The Battery Pack Database at BatteryDesign.net is a curated dataset of production battery packs. At version 1.7 it covers more than 1,800 packs across a wide range of applications: BEV and PHEV road cars, HEV, two-wheelers, commercial vehicles, home energy storage, commercial BESS, and grid-scale systems. Each record captures cell chemistry, cell format, pack architecture, and application category, among other parameters. That breadth makes it possible to identify real market patterns rather than relying on general assumptions about what chemistry or format is used where.
The chart below maps cell format against chemistry for each application category in the database.
Several clear patterns emerge from the data:
Key points
- Prismatic is the most versatile format, appearing across all applications and all major chemistries. Its flat sides simplify thermal management and structural integration in both automotive and stationary applications.
- Cylindrical cells are used almost exclusively with NCA or NMC chemistry. The wound construction and ability to contain high internal pressure suit high-energy cathodes well. Cylindrical LFP is less common because the lower energy density of LFP makes the format less competitive against prismatic alternatives.
- Blade cells are exclusively LFP. BYD’s blade architecture is purpose-built around LFP’s flat voltage profile and thermal stability, and has not been adopted for other chemistries.
- Pouch cells appear across the widest chemistry range in BEV road cars, reflecting their flexibility in shape and the ease of adapting them to different module architectures. LFP in pouch format for BEV road cars remains rare but is not absent: the 2026 Renault Mégane E-Tech is a recent example of an LFP pouch BEV entering production, a combination that was previously uncommon outside China.
- BESS applications (home, commercial, and grid) show strong convergence on prismatic LFP. Long cycle life, thermal safety, and the cost advantage of large-format prismatic cells make this the dominant choice for stationary storage, and the database reflects that clearly.
- HEV is the only application still using NiMH in volume. This reflects the longevity of the Toyota hybrid platform and the difficulty of replacing a chemistry that has been refined across decades of production.
The full dataset behind this analysis is available in the Battery Pack Database, which is updated regularly as new production packs are released.
This post has been built based on the support of and sponsorship from: illumion, Custom Power, Quarto Technical Services, Eatron Technologies and About:Energy