Classic Chevy Pickup with a modern electric powertrain
Introducing the Electric 51 Speed Shop’s 1958 Tesla Swapped Apache Pickup. A one-of-a-kind vehicle that combines the vintage charm of a patinated, air-bagged classic Chevy pickup. With the cutting-edge performance of a Tesla Model S. This unique build seamlessly integrates a Tesla powertrain into a classic Chevrolet truck, creating a truly extraordinary driving experience. Whether you’re cruising down the highway or hauling cargo. This Tesla-swapped Apache pickup is sure to turn heads and leave a lasting impression.
The Build
Starting in the front, the front suspension is a 2nd Generation Chevrolet Camaro – 1970-1981 Model Year.
Battery
The batteries to assemble the pack were pulled out of a 16kWh Hybrid Chrysler Pacifica, but are also similar to LG Chem-produced packs used in the Chevy Volt and Bolt, keeping with the GM lean.
Rear Suspension / Drivetrain
The independent rear suspension was salvaged from an older Cadillac selected for track width. Modifications to the rear suspension include custom mounts to install the 475kW Tesla Large Drive Unit spinning at 16,000 rpm sourced from EV West kit.
The Electric 51 Speed Shop’s 1958 Tesla Swapped Apache Pickup is a true masterpiece of engineering and design. The combination of vintage style and modern performance creates a vehicle that is truly one-of-a-kind. This pickup truck offers a unique driving experience that is sure to impress both car enthusiasts and Tesla fans alike. It’s a perfect example of how classic vehicles can be modernized while preserving their original charm. This Tesla Swapped Apache pickup is a must-see for anyone who appreciates the beauty of vintage cars combined with the power and efficiency of electric vehicles.
Drivetrain Specs
Motor:
Tesla Large Drive Unit
Battery:
48kWh LG Chem custom enclosure from Chrysler Pacifica
Electric cars are becoming increasingly popular. Now it’s easier than ever to convert your traditional gasoline-powered car into an electric one with the help of an electric car conversion kit. Whether you’re a beginner or have knowledge of car maintenance. This guide will provide you with the information you need. To find the perfect electric vehicle conversion kit or parts needed for your build.
Before you choose a conversion kit to put an electric motor in your car. It’s important to understand the different types of electric vehicle motors and what they mean for your car. Most electric motor kits use an AC induction motor. As they are reliable, efficient, and require less maintenance than other types. Other popular motors include brushed DC motors and brushless DC motors. Brushless motors are generally more expensive. But offer better performance while brushed motors are less expensive which makes them ideal for beginner DIYers.
Choose the Right Electric Vehicle Conversion Kit for Your Vehicle
It is essential to pick a conversion kit that’s compatible with your vehicle. You should make sure to read the product description carefully and check compatibility accordingly. Some kits are specifically designed for certain models and years while others may be adjustable to fit different vehicles. Additionally, the motor size you pick needs to match the weight of your car. Otherwise, you risk putting too much strain on the motor or not having enough power to move it forward. To get the best performance out of your kit and keep it running smoothly. Choose a kit that’s right for your car.
Follow Best Practices for EV Conversion Projects & Safety Measures
When beginning your EV conversion, remember to keep safety a top priority. Follow all instructions and specifications for the conversion kit you’ve chosen and read manuals for the components of your car. You should also wear protective gear such as gloves, eyewear, and long sleeves. During any work on your vehicle or with power tools. Moreover, avoid working around fuel lines or wires while the car is running. Use extreme caution while cutting into your vehicle’s frame and connecting components properly. Finally, always keep in mind that electricity and plan out how you will safely interface it with other components.
After deciding on a conversion kit and installing all components. Your next step should be to create a thoughtful battery care and maintenance routine. The most important part of any electric vehicle conversion is the battery. To make sure your vehicle runs efficiently and lasts for years, you’ll need to properly maintain your battery setup. Make sure to regularly inspect each component in the system. Particularly leads, terminals, joints, and connections – for corrosion or damage that could impact performance or safety. Additionally, consider investing in a battery monitoring system so you can track power usage in real time.
Revitalizing a Classic: Transforming a 1966 Ford Mustang with ReVolt Systems Tesla Power
In an extraordinary narrative of commitment and ingenuity, the Inspire EV team from Arvada, Colorado, undertook a groundbreaking project two years ago. Their mission was to catapult a first-generation Ford Mustang into the 21st century, fusing timeless design with cutting-edge electric technology. The outcome, aptly named “High Voltage,” is not just a visually stunning Mustang but a powerful electric marvel, featuring a Tesla-powered heart.
Discovering Beauty in Neglect: The Quest for a 1965 Coupe
The journey commenced with the discovery of a neglected 1965 coupe in a scrapyard, setting the stage for a project that would push the boundaries of innovation. Overcoming the challenge of incorporating a Tesla LDU and battery packs without altering the car’s original structure required extensive research and development, culminating in a pivotal partnership with reVolt Systems.
Under the Hood: Tesla-Powered Brilliance
The internal combustion engine made way for a remarkable reVolt Systems Tesla drive unit, complemented by a Ford 9-inch differential and a Mark Williams carbon fiber driveshaft. The power-packed reVolt Systems CR-43 motor, boasting over 450kW (600hp) and 1,100+ Nm (812 lb-ft), propels the Mustang from 0 to 60 in an impressive 3 seconds.
Electrifying Performance: The Heart of High Voltage
Fueling this electric powerhouse is a custom-designed battery system comprising 16 Tesla Model S battery packs, providing 85 kWh of total capacity. Strategically placed under the hood and in the trunk, these lithium-ion batteries offer a range of 250 miles. Monitored by an Orion BMS 2 and coupled with an Elcon charger and EV Controls T2C controller, the power delivery is both precise and exhilarating.
Precision Handling: Enhancements for Driving Pleasure
With a five-fold increase in power compared to the original straight-6 engine, enhancements include a Speedway 4-link rear end and Jonny Law Motors Mustang II front end for precise handling. Top-shelf gear, such as superb Racing wheels and Riken Raptor tires, ensures optimal grip, while the lighting system features Oracle headlights and the interior is adorned with TMI Pony seats, Aurora Gauges, and a Retrosound stereo.
Overcoming Challenges: Meticulous Restoration and Electric Conversion
The restoration journey involved painstaking in-house bodywork and paint application using PPG paint, addressing the necessity of fully restoring the Mustang alongside the electric conversion. Inspire EV’s unwavering attitude and hard work were pivotal in overcoming challenges, emphasizing the importance of never accepting failure as an option.
Lessons Learned: An EV Odyssey
Converting classic cars to EVs requires extensive research, and the Inspire EV team acknowledges the invaluable support received from individuals within the EV community. Their goal was to rescue an American classic from oblivion, preserving its original appearance while incorporating the most powerful electric motor available. The result is High Voltage – a vehicle that not only accelerates impressively but also delivers an exhilarating driving experience.
The Road Ahead: High Voltage on Tour
As the team at Inspire EV concludes this remarkable chapter, they invite enthusiasts to witness the power and beauty of their creation firsthand. High Voltage will tour major EV shows in the US this year and the next, standing out as an exceptionally attractive “Tesla” on the road, a true testament to their remarkable achievement.
Project One More Wire came into existence with the collaboration of Mark and Logan, driven by their shared enthusiasm for an exciting venture. Seeking expert assistance from the team at Legacy EV, they were equipped with the necessary resources, including training and equipment, to undertake the electric vehicle aspect of their ambitious project.
A Moving Masterpiece in the Making
Presently, the El Camino is a work in progress, with ongoing paint and bodywork enhancements. The anticipation for its completion and the prospect of taking it for a spin is palpable, as it promises to be a true marvel in motion.
Power and Precision: The Electric El Camino’s Performance
The Electric El Camino boasts the might of two NetGain Hyper9 motors operating in unison, delivering a substantial 186 kW and an impressive 880 Nm of torque. Custom motor and transmission mounts, in conjunction with the Thunderstruck Motors control system and software, ensure precise control and smooth power delivery. This mighty machine can unleash its full power for exhilarating burnouts with ease, effortlessly annihilating a set of Goodyear Eagle 225/45R18 tires in seconds.
Uninterrupted Power Flow with a Modular Battery Pack
To harness all this power, the car features a modular battery pack comprising custom-configured prismatic cells by Vintage Iron, providing a remarkable 66.6 kWh of capacity and dual onboard chargers. With the plug conveniently located in the factory fuel fill location, recharging is a breeze, making sure you’re never left stranded.
Riding in Style: The Custom Chassis and Suspension
The Electric El Camino’s custom chassis and 1992 Ford Thunderbird independent suspension deliver a smooth and stable ride. The lowered design and coilover setup offers a classic, sporty appearance, complemented by American Racing wheels, Eagle tires, and reliable Wilwood brakes. The custom-made aluminum driveshaft ensures durability and longevity.
Modern Comfort and Technology Inside
Beyond its impressive performance, the interior of the Electric El Camino has also been updated to meet 21st-century standards. A custom-built HVAC system, a stylish Budnick steering wheel, reupholstered seats, and Dakota Digital gauges enhance the driving experience.
EV West’s built Custom 1964 Chevrolet Corvette utilizing a Tesla Model S small drive unit mounted in the rear in a custom subframe, with a custom battery enclosure mounted up front where the factory big block 427ci 4 Speed once sat.
EV West has undertaken a remarkable project by transforming a classic 1964 Chevrolet Corvette into a cutting-edge electric vehicle, combining the nostalgia of the past with the technology of the future. The heart of this project lies in the innovative use of a Tesla Model S small drive unit, ingeniously placed in the rear of the vehicle within a custom subframe. This electric drivetrain not only preserves the iconic silhouette of the Corvette but also enhances its performance and environmental sustainability.
One of the most distinctive features of this electric Corvette is the placement of the custom battery enclosure at the front, where the legendary big block 427ci V8 engine and 4-speed transmission used to reside. In order to preserve this classic while outfitting it with a modern full electric drivetrain, the chassis remains in factory condition in order to allow for the factory powerplant to be reinstalled if needed.
What makes this conversion truly exceptional is the commitment to preserving the classic Corvette’s integrity. The original chassis remains untouched, allowing the option to revert to the factory powerplant if desired. This forward-thinking approach respects the vehicle’s heritage while providing an exciting glimpse into the future of classic car restoration.
Tony Hawk’s EV West’s custom built 1964 Chevrolet Corvette is a testament to the intersection of classic automotive design and sustainable technology. By seamlessly integrating electric propulsion into a timeless masterpiece, they have demonstrated the potential for preserving automotive history while embracing the green revolution. This project not only showcases the possibilities of electric conversions but also highlights the importance of adaptability in the ever-evolving world of automotive engineering.
Drivetrain Specs
Motor:
Tesla Model S Small Drive Unit Custom Rear Subframe
The Ultimate Custom Electric Truck Unveiled, Blending Power, Style, and Cutting-Edge Innovation
Custom Electric Truck: Power, Style, and Innovation
In a world that’s increasingly turning to electric vehicles for a more sustainable future, a custom electric truck has emerged as a testament to the marriage of power, style, and innovation. This project from the folks at Foremost EV boasts impressive specifications, bringing together cutting-edge technology and classic design in a truly remarkable way. From its dual motors producing nearly 700 lb-ft of torque to its sleek vinyl wrap and vintage air suspension system, this custom build is nothing short of extraordinary.
Dual Motors for Electrifying Performance
At the heart of this custom electric truck are its dual Hyper 9 motors connected to a Torque Trends Torque Box sourced from Legacy EV which work in harmony to deliver an astonishing 692 lb-ft of torque instantaneously. This immense torque, combined with 260 horsepower, propels the truck forward and puts the power to the ground with a modified 1992 Ford Thunderbird Independent Rear Suspension. With a 78kWh battery pack, the vehicle manages to offer an estimated range of 180-200 miles on a single charge, making it a practical choice for daily driving.
Stylish Exterior Makeover
The aesthetics of this electric truck have been completely revamped, giving it a sleek and modern look. A satin pearl white full vinyl wrap not only provides a head-turning appearance but also protects the underlying body. In addition, all the chrome accents have been powder-coated black, adding a touch of stealthy sophistication. The custom smoothie black wheels measuring 15×8 inches, wrapped in Mickey Thompson tires, enhance the overall aesthetics while ensuring a firm grip on the road.
Innovative Suspension and Braking
The vehicle is equipped with a full air ride suspension, allowing an adjustable and comfortable ride. This air system not only provides a smooth and enjoyable driving experience but also adds an extra layer of versatility to the vehicle’s capabilities. For added performance, the braking system has been upgraded with drilled and slotted disc brake conversion, ensuring the ability to stop on a dime.
Revamped Interior Comfort
Step inside, and you’ll find a stunning suede interior that covers the seats, headliner, and door inserts. The fresh carpet and padding not only provide comfort but also absorb noise, creating a quiet and peaceful cabin. This attention to interior details ensures that passengers are not only treated to a smooth and silent ride but also a luxurious one.
Innovative Upgrades
This custom electric truck doesn’t stop at just the basics. It features an aftermarket vintage air system, which not only keeps the cabin comfortable but also adds a touch of nostalgia and uniqueness. The inclusion of ‘Tough Skin’ sprayed bed-liner, extending from under the hood to the engine, protects and adds durability to the vehicle. The Ford 9″ differential and a complete Mustang II front-end add to the vehicle’s robust performance and handling.
Concluding Thoughts
The custom electric truck showcased here is a true marvel of modern engineering and design. It fuses the power of dual motors, sleek aesthetics, and innovative features to create a vehicle that is not only impressive in performance but also a work of art on wheels. This project demonstrates the limitless possibilities of electric vehicle customization, making a strong case for the future of eco-friendly transportation that doesn’t sacrifice style or power.
Specifications:
Motor: (2) Hyper 9 motors
Torque: Torque Trends torque box
Horsepower: 260 hp
LBFT Torque: 692 LBFT torque
Battery Pack: 78kWh battery pack
Estimated range: 180-200 miles
Wrap: Satin pearl white full vinyl wrap
Powder Coat: All chrome powder-coated black
Climate Control System: Aftermarket vintage air system
Interior: Suede interior on seat, headliner, and door inserts
Interior Carpet: Fresh carpet and padding
Wheels & Tires: 15×8 smoothie black wheels with Mickey Thompson tires
Brakes: Drilled and slotted disc brake conversion
Suspension: Full-air ride setup
Bed-Liner: ‘Tough Skin’ sprayed in bed-liner and under the hood
Differential: Ford 9” differential
Front End: Complete Mustang II front-end
Rear Suspension: Heavy duty chopping block parallel 4-link rear suspension
Designed and developed in partnership with Nissan. The Ariya AT39 (Arctic Trucks®, 39“tire) is a professionally re-engineered high mobility platform, balancing the performance and efficiency of Nissan‘s electric vehicle architecture. With adaptations and enhancements to the body, bodywork, subframe, underbody, suspension, steering, wheels, tires, braking system, and more. To create a truly long-range expedition vehicle capable of circumnavigating the globe, over all terrains, with minimal environmental footprint.
Key features include:
Arctic Trucks® re-engineering to frame, body, bodywork, underbody, steering, and braking systems
Suspension optimized and elevated by Arctic Trucks®, incorporating repositioning and geometry adjustment to suspension mounting points and subframe (elevation: +110mm)
Electronic headlight adjustment and speedometer recalibration
Enlarged and strengthened mudguards
Multiple Arctic Trucks® strengthened 2” multifunction receiver hitches (front and rear), for mounting of towing, winching, gear carrying solutions, expedition accessories etc.
Range
Between the huge off-road tires, fenders, and roof rack with rooftop tent, the range has been cut significantly. According to GPS. The longest they’ve gone so far between charges is about 162 miles. With 18% left in the battery, giving them a “best” achieved range of ~200 miles out of the 272-mile rated Ariya.
Hot weather can cause EV batteries to degrade faster. But there are some simple things owners can do to help protect their cars.
Recurrent publishes battery health reports for used EVs, but also uses the data pulled from vehicles to study the impact of hot and cold weather on range and battery health. In a recent study of Tesla models, it was found that cars based in hot climate zones generally lose more range as they age than cars in cold climate zones.
That’s because higher levels of environmental heat contribute extra energy to the electrochemical reactions that make a battery work. This “can accelerate unwanted chemical reactions that age the battery prematurely,” according to Recurrent. The company has found that cold weather causes range loss but notes that cold temperatures are unlikely to cause permanent damage. The “generally accepted” threshold for accelerated battery degradation is around 86 degrees Fahrenheit
EV (Electric Vehicle) batteries can indeed degrade faster in hot weather, and this degradation can lead to reduced range and overall battery lifespan. However, there are several steps EV owners can take to mitigate the effects of hot weather on their batteries:
Park in the Shade: Whenever possible, park your EV in a shaded area to reduce the exposure to direct sunlight and high temperatures. This can help keep the battery cooler and prevent excessive heat-related degradation.
Use Climate Control Strategically: Using the air conditioning in your EV can help keep the cabin cool, but it also consumes energy from the battery. Pre-cool your EV while it’s still plugged in and charging to minimize the use of battery power for cooling once you’re on the road.
Limit Fast Charging in Extreme Heat: High-speed DC fast charging generates more heat, which can be detrimental to the battery. If you’re on a long trip and need to use fast chargers, try to do so during cooler parts of the day or night when temperatures are lower.
Maintain Proper Tire Pressure: Ensure that your tires are inflated to the manufacturer’s recommended pressure. Underinflated tires can increase rolling resistance, which can cause the battery to work harder and generate more heat.
Avoid Extreme Driving: Aggressive driving, such as rapid acceleration and high-speed driving, can generate more heat in the battery. Drive conservatively to reduce stress on the battery.
Limit Exposure to High Temperatures: If you live in an area with consistently high temperatures, consider using a car cover or parking your EV in a garage to shield it from the heat when not in use.
Battery Management System: Trust the battery management system (BMS) of your EV. Modern EVs are equipped with sophisticated BMS software that manages the temperature and state of charge to optimize battery life. Avoid manually charging or discharging the battery excessively unless it’s necessary.
Regular Maintenance: Follow the manufacturer’s recommended maintenance schedule for your EV, including battery maintenance if specified. Some EVs may require periodic coolant checks or other maintenance to keep the battery operating optimally.
Software Updates: Keep your EV’s software up to date. Manufacturers often release software updates that can improve battery management and overall performance.
Plan Charging: When planning long trips in hot weather, consider charging your EV to a slightly lower state of charge (SoC) before reaching your destination. This can help reduce the heat generated during the charging process.
Remember that while these tips can help mitigate the effects of hot weather on EV batteries. All batteries degrade over time. It’s a natural process, and the rate of degradation can vary depending on usage, environmental conditions, and battery technology. If you have concerns about your EV’s battery health, consult your vehicle’s manual or contact the manufacturer for specific guidance and recommendations.
There’s a new world record for the fastest 0 to 62 mph (0–100 km/h) for an electric vehicle, courtesy of a team of students at the Academic Motorsports Club Zürich and the Swiss universities ETH Zürich and Lucerne University of Applied Sciences and Arts. The team did so with a scratch-built EV, designing everything from its chassis to its circuit boards, and besting the existing record.
Called the “Mythen” all components, from the printed circuit boards (PCBs) to the chassis and the battery, were developed by the students themselves and optimized for their function. Thanks to the use of lightweight carbon and aluminum honeycomb, the race car weighs in at only around 140 kilos (309 pounds). Four-wheel hub motors that the students developed themselves and a special powertrain give the vehicle its impressive power of 240 kilowatts or around 326 hp.
“But power isn’t the only thing that matters when it comes to setting an acceleration record – effectively transferring that power to the ground is also key,” says Dario Messerli, head of aerodynamics at AMZ. Conventional Formula One cars solve this through aerodynamics: a rear or front wing pushes the car to the ground. However, this effect only comes into play when the car has reached a certain speed. To ensure strong traction right from the start, the AMZ team has developed a kind of vacuum cleaner that holds the vehicle down to the ground by suction.
The shape is not the only thing that differentiates prismatic and cylindrical cells. Other important differences include their size, the number of electrical connections, and their power output.
We’ll take a look at the core differences between cylindrical, prismatic, and pouch cells for batteries to understand how they interact with other tools and devices. Review a comparison of cylindrical cells with prismatic pouch cells. Look at the pros and cons of each type of battery packaging style, and learn some of the industrial uses that each kind of cell is best suited for.
Cylindrical vs. Prismatic vs. Pouch Cells – For anyone interested in the basic differences among cylindrical, prismatic, and pouch cells. Here’s a general breakdown of how and why these different battery packaging designs were created
Cylindrical Cells
Tubular-shaped lithium-ion or nickel-based cylindrical cells number among the most popular batteries in use today. Their popularity stems from the fact that cylindrical cells are inexpensive to produce, widespread, stable, and safe to use. And can be applied uniformly across a variety of industries (i.e. they aren’t manufacturer-specific in shape and design).
Cylindrical lithium cells, which come with a very manageable watt-per-hour price, are a mainstay for portable gadgets and mobile tech. It’s probably a good idea to note that the electric car manufacturer Tesla has (literally) fueled the demand for cylindrical cells (18650 and the slightly larger 21700 cells). This demand is based on the company’s 2008 decision to use cylindrical cells. Instead of specially designed prismatic or pouch cells. That being said, Tesla isn’t 100% averse to using other types of batteries, as is the case for Tesla Model 3s made in China.
Prismatic Cells
Lithium-ion (Li-ion) battery prismatic cells are thinner and lighter than cylindrical cells. These cells, coming in rectangular aluminum or steel casing (“cans” that increase stability), have fairly long lifespans.But aren’t as easy to keep cool compared to their cylindrical counterparts.
Prismatic cells, while thin and light, don’t come in a uniform, standard design. This fact means they can be quite costly to manufacture, coming with a higher watt-per-hour price point. Yet the prismatic cells’ variable shapes and sizes offer engineers more design flexibility, and the ability to layer them (thanks to their rectangular shape) They can limit the amount of valuable space they take up in products like mobile phones and tablets.
One disadvantage of prismatic cells is that if an issue arises with any one cell in a battery pack (likely due to thermal management difficulties), the entire pack will be in trouble.
However, the EV industry evolves quickly, and it’s uncertain whether prismatic cells or cylindrical cells will prevail. At the moment, cylindrical cells are more widespread in the EV industry. But there are reasons to think prismatic cells will gain popularity.
First, prismatic cells offer an opportunity to drive down costs by diminishing the number of manufacturing steps. Their format makes it possible to manufacture larger cells. Which reduces the number of electrical connections that need to be cleaned and welded.
Prismatic batteries are also the ideal format for the lithium-iron-phosphate (LFP) chemistry. A mix of materials that are cheaper and more accessible. Unlike other chemistries, LFP batteries use resources that are everywhere on the planet. They do not require rare and expensive materials like nickel and cobalt that drive the cost of other cell types upward.
There are strong signals that LFP prismatic cells are emerging. In Asia, EV manufacturers already use LiFePO4 batteries, a type of LFP battery in the prismatic format. Tesla also stated that it has begun using prismatic batteries manufactured in China for the standard range versions of its cars.
The LFP chemistry has important downsides, however. For one, it contains less energy than other chemistries currently in use and, as such, can’t be used for high-performance vehicles like Formula 1 electric cars. In addition, battery management systems (BMS) have a hard time predicting the battery’s charge level.
Pouch Cells
When comparing pouch cells with prismatic cells, one of the main differences to pay attention to is the lack of aluminum or steel casing. Instead, soft-pack pouch-cell lithium batteries are enclosed in a soft polymer aluminum plastic film or shell, which makes them very lightweight.
Lithium-polymer batteries (LiPo) make use of a polymer electrolyte rather than a liquid electrolyte. These batteries are increasingly popular with smartphone manufacturers. Their soft lightweight design also offers more safety measures than hard metal casings. When a critical issue with a pouch cell occurs – often due to internal pressure overheating or shortening the batteries – the pack will noticeably expand with gas. But the oversized pack won’t explode, which can happen with a hard aluminum or steel case.
High energy density pouch cells, due to their custom-built nature, light packaging, reliability, and small size are well-suited for automotive use, radio-controlled aircraft and cars, drones, and ultra-thin laptops.
Additionally, pouch cells are also used in technologies where weight and safety are an issue but a decent cycle life (how many times a battery or battery pack can be charged before it dies) and high energy density are also desired. Still, be aware that pouch cells cost more than lithium-ion batteries and often come with slightly less storage power, plus a shorter lifespan.
Comparing Cylindrical Cells with Prismatic Batteries and Pouch Cells
Now that you have some idea about the technology behind these different types of battery packaging. Let’s dive a little deeper into a comparison between cylindrical cells, prismatic batteries, and pouch cells.
Here are some of the main pros and cons you should look for when thinking about cylindrical vs. pouch cells. But of course, the type of cell you ultimately choose will depend on the type of application you need it for.
Cylindrical cells, due to their widespread and standardized use. Offer a more robust automation process and better manufacturing techniques (providing a more consistent product) than pouch cells.
Prismatic pouch cells are sensitive to deformation in high-pressure environments. Whereas cylindrical cells handle high internal pressures much better and without deforming.
Cylindrical lithium battery electrodes are easier to weld when compared with lithium polymer pouch cells or prismatic cells.
Pouch cells, while lightweight, are vulnerable to damage stemming from humidity and high temperatures. This can reduce their lifespans and increase their overall cost because they’ll need to be replaced more often.
If a single cylindrical battery goes bad, the impact on the entire pack is relatively low. But with prismatic cells, if one battery goes bad, it can then compromise the entire pack.
Cylindrical cells are stable, inexpensive, standardized across industries, and last a long time (thanks to better cycling). Prismatic cells and pouch cells are not standardized across industries, which makes them more expensive to produce. That said, their rectangular shapes utilize limited space better, and those with hard shells can be stacked. In most cases, softer pouch cells should not be stacked.
Cylindrical batteries radiate heat and control temperature more effectively when compared to prismatic batteries. Prismatic batteries die faster due to less effective thermal management.
The chemical activity at the edges and corners of prismatic batteries is rather poor. The less-than-optimal chemical activity of prismatic batteries means their performance decreases substantially after long-term use. Cylindrical batteries have a much longer lifespan compared to prismatic batteries.
Cylindrical cells, along with prismatic and pouch cells, all come with different advantages and disadvantages depending on their intended use. As battery packaging technologies change and continue to improve (e.g., removing rare and expensive cobalt from lithium-ion battery designs). These advantages and disadvantages will likely change as well.
The Main Differences Between Prismatic and Cylindrical Cells
The shape is not the only thing that differentiates prismatic and cylindrical cells. Other important differences include their size, the number of electrical connections, and their power output.
Size
Prismatic cells are much larger than cylindrical cells and hence contain more energy per cell. To give a rough idea of the difference. A single prismatic cell can contain the same amount of energy as 20 to 100 cylindrical cells. The smaller size of cylindrical cells means they can be used for applications that require less power. As a result, they are used for a wider range of applications.
Connections
Because prismatic cells are larger than cylindrical cells, fewer cells are needed to achieve the same amount of energy. This means that for the same volume, batteries that use prismatic cells have fewer electrical connections that need to be welded. This is a major advantage for prismatic cells because there are fewer opportunities for manufacturing defects.
Power
Cylindrical cells may store less energy than prismatic cells, but they have more power. This means that cylindrical cells can discharge their energy faster than prismatic cells. The reason is that they have more connections per amp-hour (Ah). As a result, cylindrical cells are ideal for high-performance applications whereas prismatic cells are ideal to optimize energy efficiency.
Examples of high-performance battery applications include Formula E race cars and the Ingenuity helicopter on Mars. Both require extreme performances in extreme environments.
The best Lithium-ion cell type for your EV Swap depends on the specific application and usage requirements. Factors to consider include energy density, power density, cycle life, and cost. Some common types of Lithium-ion cells include Lithium Cobalt Oxide (LiCoO2), Lithium Manganese Oxide (LiMn2O4), Lithium Iron Phosphate (LiFePO4), and Lithium Nickel Manganese Cobalt Oxide (LiNiMnCoO2). Ultimately, the best type of Lithium-ion cell will depend on the intended use and the specific requirements of the application.
