Cell formats, grading and how a pack is built — the choices that decide cost and life.
Cylindrical, prismatic and pouch cells
Prismatic cells dominate storage, cylindrical cells dominate light EV. The format fixes the BMS and the enclosure.
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Grading, matching and pack assembly
Matched cells and clean welding decide whether the pack balances for years or fights itself from day one.
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Questions
Short answers to the ones that come up most.
What cell format should I choose?
Prismatic for storage and traction, cylindrical for light EV and tools, pouch where space is irregular. The format then decides the BMS and enclosure.
Does cell grading matter?
Yes — Grade A cells are matched and tested; assembling unmatched cells is the most common cause of early pack failure.
How are cells connected?
Spot-welded nickel strip or bolted busbars. Bolted connections are serviceable; welded ones are cheaper and more compact.
