Choosing the right battery cell and chemistry is one of the most important decisions when developing electric equipment. Different applications place different demands on a battery, and selecting the wrong technology can lead to unnecessary costs, reduced equipment performance and integration challenges.
For original equipment manufacturers (OEMs), the decision goes beyond battery capacity or energy density. Operating conditions, duty cycles, charging opportunities, safety requirements and expected service life all influence which cell technology is most suitable.
At Lithion, we start by understanding how the equipment will operate, then use those requirements to guide cell chemistry and format selection before developing the battery pack architecture. This helps OEMs balance performance, reliability, safety and total cost of ownership from the outset.
Lithium-ion batteries are available in several chemistries, each offering different performance characteristics and trade-offs.
Three commonly considered technologies for industrial electrification are lithium iron phosphate (LFP), nickel manganese cobalt oxide (NMC) and lithium titanate (LTO)-based cells.
LFP batteries are known for their thermal stability, long cycle life and competitive cost.
These characteristics make them attractive for industrial equipment that experiences frequent charging and discharging, including ground support equipment (GSE), material handling vehicles and stationary energy storage systems.
However, LFP generally offers lower energy density than NMC, which can increase the size or weight of a battery pack for a given energy capacity.
NMC batteries typically offer higher energy density, making them suitable for applications where space and weight are important considerations.
This can be valuable for electric vehicles, mobile robotics and other equipment where battery packaging is limited.
However, factors such as cycle life, thermal management, charging performance and cost must be evaluated against the application's operating requirements. Actual performance depends on cell design and operating conditions.
LTO-based cells use lithium titanate as the anode material, rather than representing a cathode chemistry in the same way as LFP or NMC.
They are known for their rapid charging capability, long cycle life and strong performance in demanding operating conditions.
These characteristics can make them suitable for applications requiring frequent charging or high cycling.
However, LTO-based cells generally have lower energy density and higher upfront costs, making them less attractive where battery size, weight or initial purchase price are the main priorities.
Each chemistry offers different advantages depending on the application.
These comparisons are general guidelines rather than fixed specifications. Actual battery performance depends on the selected cell, battery pack design, charging strategy and operating conditions.
All lithium-ion chemistries require appropriate electrical protection, thermal management and battery management systems.
In addition to chemistry, OEMs must consider the physical format of the battery cells.
Three common formats are prismatic, cylindrical and pouch cells. Each has different implications for packaging, mechanical protection, thermal management and manufacturing.
Prismatic cells use a rigid, typically rectangular enclosure.
Their shape can support efficient packaging within a battery module or pack, making them attractive for applications where space utilisation is important.
However, their size and construction require appropriate consideration of thermal management, mechanical support and cell expansion.
Cylindrical cells use a rigid metal enclosure and are widely used across lithium-ion battery applications.
Their standardised shapes and mechanical characteristics can offer advantages for manufacturing and module design.
However, packs using cylindrical cells may require larger numbers of individual cells and connections, depending on the required capacity and power output.
Pouch cells use a flexible laminated enclosure, offering packaging and weight advantages in certain applications.
However, they require careful consideration of mechanical support, swelling, thermal management and protection within the battery pack.
No cell format is inherently safe simply because of its shape. Each must be evaluated as part of the complete battery system.
Choosing the right battery cell starts with understanding how the equipment will operate.
For OEMs, this means looking beyond battery capacity and considering the complete duty cycle, including continuous and peak power demands, operating temperatures, charging opportunities, available space and expected service life.
At Lithion, we use these requirements to guide cell chemistry and format selection before developing the battery pack architecture.
For example, an electric baggage tractor operating throughout an airport shift may have different battery requirements from a cargo loader that experiences short periods of high power demand.
Similarly, equipment that can take advantage of frequent charging opportunities may benefit from a different battery configuration than equipment that must operate for an entire shift without recharging.
Key considerations include:
Considering these requirements early helps OEMs avoid overspecifying battery systems or selecting technology that is poorly suited to the equipment's operating demands.
The lowest upfront battery price does not always deliver the lowest cost over the equipment's operating life.
Battery chemistry and cell selection can influence maintenance requirements, charging infrastructure, equipment availability and replacement intervals.
For OEMs and fleet operators, the total cost of ownership should consider several factors:
For example, a higher-cost battery chemistry may offer better overall value if its charging capability or service life improves equipment availability and reduces replacement costs.
Equally, a more affordable chemistry may be the better choice where charging opportunities are sufficient and operating demands are less intensive.
The objective is not necessarily to select the battery with the highest energy density, fastest charging or longest theoretical cycle life. It is to identify the most appropriate solution for the application at a commercially sustainable cost.
Selecting the right cell and chemistry is about more than comparing technical specifications. It's about understanding how the battery will perform within the equipment throughout its expected operating life.
Lithion works with OEMs to understand their equipment requirements, duty cycles, charging strategies and operating environments before selecting the appropriate cell chemistry and developing the battery pack.
By considering performance, safety, integration and lifecycle costs from the outset, we help customers avoid unnecessary complexity, reduce development risks and select battery solutions that support reliable, cost-effective electrification.
Whether developing new electric equipment or converting existing vehicles, our approach is to design battery solutions around the application rather than expecting the application to fit the battery.
Developing new electric equipment or planning an existing vehicle conversion?
Contact Lithion to discuss your battery requirements and how the right cell selection can support your electrification strategy.
