Which Cell Shape Is Best for an Electric Formula Car?

In the split-second world of electric formula racing, every component is pushed to its limit. The battery pack, the car’s heart and a major source of weight, demands perfection. Engineers face a critical design decision: which lithium-ion cell shape is best for an electric formula car?

The choice between cylindrical, prismatic, and pouch cells directly impacts power, weight, safety, and layout. As a leader in high-performance battery solutions, we analyze the ultimate choice for the track.

The Three Contenders: Key Technologies Compared

Three cell architectures dominate, each with distinct trade-offs for racing applications.

1. Cylindrical Cells (e.g., 21700, 4680)

These familiar steel-cased cells offer robust mechanics and proven manufacturing.

تسلا‘s Model 3 uses this type of battery, requiring a powerful battery management system (BMS) to maximize its performance.

Strengths: Superior mechanical stability; cost-effective, automated production with high consistency; natural gaps between cells aid cooling.
Weaknesses: Lower pack density due to empty spaces; heavier weight from casings and supports; inflexible form factor.

2. Prismatic Cells

These rigid, rectangular cells with aluminum casing are common in consumer EVs.

Strengths: Better space use than cylindrical cells in modular layouts; easy to stack and assemble.
Weaknesses: Heavier than pouch alternatives; potential swelling requires careful module design; thermal interface challenges.

3. Pouch Cells

Cells using lightweight, flexible aluminum-laminate packaging instead of hard casings.

Strengths: Highest energy and power density by weight and volume; lightweight design; flexible shape for optimal packaging; excellent thermal dissipation from large surfaces.
Weaknesses: Requires external module structure for support; needs precise pressure management to control swelling; sealing is critical for reliability.

Diagram depicting three types of battery cells: cylindrical, prismatic, and pouch, each labeled with components such as terminals, case, anode, cathode, and separator.

Why Pouch Cells Win in Electric Formula Racing

For the extreme demands of a formula car, pouch cells are the clear winner among leading racing teams. Here’s why:

1. Unbeatable Power-to-Weight Ratio: Racing success hinges on this metric. Pouch cells eliminate heavy metal casings, making them the lightest option per unit of energy (Wh/kg) and power (W/kg). Reducing weight directly improves acceleration, top speed, and cornering.

2. Superior Packaging and Low Center of Gravity: Their flat, adaptable shape lets engineers create dense, low-profile packs. Teams can place these packs along the chassis floor to maximize capacity while dramatically lowering the center of gravity. This enhances stability and grip through corners.

3. Peak Discharge and Regeneration Performance: Pouch cells typically feature lower internal resistance. This allows for breathtaking peak power output and highly efficient regenerative braking—both non-negotiable for the explosive sprints and energy recovery of formula racing.

4. Efficient Thermal Management: The large, flat surfaces of pouch cells perfectly interface with liquid cooling plates. This design pulls heat away rapidly and uniformly, preventing performance throttling during intense qualifying laps or long races.

The Engineering Imperative

Choosing pouch cells requires a commitment to advanced engineering. Their benefits only materialize with:

Advanced Module Design: A rigid, lightweight structure must apply precise stack pressure to manage swelling and ensure electrical contact.
Robust Thermal Systems: Direct, uniform cooling via advanced cold plates is essential.
Stringent Quality Control: Cell-to-cell consistency in thickness, capacity, and resistance is vital for pack balance under extreme stress.

Conclusion: Integration is Everything

While pouch cells provide the highest performance potential, victory is secured at the system level. The best cell is the one perfectly integrated into a pack designed for relentless power, efficient cooling, and structural integrity.

At LiYue Battery, we specialize in this integration. We provide ultra-high-power pouch cells for electric formula cars and engineer complete solutions—including structural modules, liquid cooling systems, and robust BMS—to power the future of electric racing.

Ready to push the limits of performance? Contact us to power your next winning project.