Design and production trade-offs in lithium-ion batteries from cell formats to electric vehicles

Sustainable energy systems demand energy-dense, scalable, manufacturable, and readily integrable lithium-ion batteries, yet available literature provides fragmented comparisons of commercial cell formats. Here we report a unified, industrially grounded benchmarking framework for cylindrical, pouch, and prismatic cells using parameters selected for high-fidelity derivability across formats and direct relevance to manufacturing and system integration. At cell level, active/inactive volume allocation, gravimetric and volumetric energy densities, and assembly complexity are quantified. At pack level, we evaluate nominal voltage and capacity, pack energy, gravimetric cell-to-pack ratio, cooling, and structural integration descriptors. Chemistry-dependent single-cell and pack-scaled costs are estimated from prospective cost trajectories. Fast-charging capability, resistance growth and aging, and quantitative thermal performance are excluded due to noncomparable datasets; pack thermal implications are discussed qualitatively. The framework shows cylindrical lithium nickel manganese cobalt oxide cells maximizes cell-level energy density but increases structural overhead, whereas lithium iron phosphate blade designs maximize cell-to-pack ratio, pack volumetric energy, and cost competitiveness.