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Battery Pack Sizing Calculator

Find the limitation before it becomes an expensive problem!

Size a battery pack from cell to vehicle in one place

PackForge turns a cell datasheet into a full pack model — energy, power, mass, cost, thermal limits, cycle life, and design risks — so you can trade off configurations without rebuilding a spreadsheet every time. Start from a commercial preset or a custom cell and iterate live.

  1. Pick a cell

    Choose a production cell from the library or enter custom specs.

  2. Set the architecture

    Define series/parallel at module and pack level, then vehicle targets.

  3. Read the results

    See energy, power, mass, cost, and risk update live as you design.

Configuration

Name and save this pack configuration for later comparison.

Cell

Manufacturer
AESC
Part number
LMO-32.5Ah-Pouch
Cell parameters (auto-populated)
Chemistry
LMO
Form factor
Pouch
Nominal voltage
3.75V
Voltage range
2.5–4.2V
Capacity
32.5Ah
Energy
121.9Wh
Mass
790g
Est. cost
$20
Cost / energy
$164.1/kWh
Peak power density
617W/kg
Continuous power density
427W/kg
Cost / peak kW
$41/kW
Cost / continuous kW
$59.3/kW
Cycle life
800–1500cycles

1C/1C, 100% DoD, 25°C, 2.5–4.2V (hot climates degrade faster)

Cell ratings
Discharge
Continuous(2.77C @ 25°C)
90.0 A337.5 W
Peak(4.00C @ 25°C)
130.0 A487.5 W
Charge
Continuous(1.08C @ 25°C)
35.0 A131.3 W
Peak(1.85C @ 25°C)
60.0 A225.0 W

Architecture

Module

Resulting nominal: ≈ 90.0 V

Blank estimates the mass from the cell, structure and cooling. Enter the module's own mass to override.

Module current ratings

Leave blank to derive from the cell rating × 6 in parallel, or enter the module's own rating.

Pack

Auto-sized from the vehicle voltage window and target power, based on the selected module.

7auto
1auto
Resulting pack: 630.0 V nominal · 420.0–705.6 V range
✓ Pack max 705.6V ≤ system max 800V
✓ Pack min 420.0V ≥ system min 400V

Vehicle

1auto

Cooling approach

Results

Cell current

Cell current 39.7A within continuous 90A limit.

Voltage window

Pack max 705.6V within bus limit 800V. Pack min 420.0V within bus limit 400V.

Thermal

Continuous 1.22C is near the Air Cooling limit (1.5C). Expect elevated cell temperatures under sustained load.

Cycle life

Short-to-moderate cycle life (~800 cycles to 80%). Mid-life replacement may be needed under heavy daily use; lifetime cost per kWh exceeds long-life chemistries (LFP/LTO).

Module

144 cells (24S × 6P) · Air Cooling

Voltage
90.0V
Voltage range
60.0–100.8V
Total energy
17.6kWh
Cell mass
113.8kg
Structure mass
8.0kg
Cooling mass
1.8kg
Total mass
123.5kg
Cost
$3,062*
Cost / energy
$174.5/kWh*
Peak power density
569W/kg
Continuous power density
394W/kg
Cost / peak kW
$43.6/kW*
Cost / continuous kW
$63.0/kW*

* Estimated cost, modeled from the cell, structure and cooling models

Module ratings
Discharge
Continuous(2.77C @ 25°C)
540.0 A48.6 kW
Peak(4.00C @ 25°C)
780.0 A70.2 kW
Charge
Continuous(1.08C @ 25°C)
210.0 A18.9 kW
Peak(1.85C @ 25°C)
360.0 A32.4 kW
Pack

7 modules (7S × 1P) · Air Cooling

Voltage
630.0V
Voltage range
420.0–705.6V
Total energy
122.9kWh
Modules mass
864.3kg
Structure mass
110.6kg
Cooling mass
49.1kg
Electrical mass
20.0kg
Total mass
1,044.1kg
Cost
$22,148*
Gravimetric density
117.7Wh/kg
Cost / energy
$180.3/kWh*
Peak power density
471W/kg
Continuous power density
326W/kg
Cost / peak kW
$45.1/kW*
Cost / continuous kW
$65.1/kW*

* Estimated cost, modeled from the cell, structure and cooling models

Pack ratings
Discharge
Continuous(2.77C @ 25°C)
540.0 A340.2 kW
Peak(4.00C @ 25°C)
780.0 A491.4 kW
Charge
Continuous(1.08C @ 25°C)
210.0 A132.3 kW
Peak(1.85C @ 25°C)
360.0 A226.8 kW
Vehicle

1 pack in parallel

Voltage
630.0V
Total energy
122.9kWh
Mass
1,044.1kg
Cost
$22,148*
Pack density
117.7Wh/kg
Cost / energy
$180.3/kWh*
Peak power density
471W/kg
Continuous power density
326W/kg
Cost / peak kW
$45.1/kW*
Cost / continuous kW
$65.1/kW*
Cell cycle life
800–1500cycles

* Estimated cost, modeled from the cell, structure and cooling models

Cycle test: 1C/1C, 100% DoD, 25°C, 2.5–4.2V (hot climates degrade faster)

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PackForge provides engineering estimates only. Actual performance, mass, cost, and lifetime depend on cell lot variation, manufacturing, thermal management, and operating conditions. Verify all results against manufacturer datasheets and qualified testing before use. PackForge is not liable for errors, omissions, or any decisions made using these calculations.