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PackForge

Battery Pack Sizing Calculator

Find the problem 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

ManufacturerAESC
Part numberLMO-32.5Ah-Pouch
Cell parameters (auto-populated)
ChemistryLMO
Form factorPouch
Nominal voltage3.75V
Voltage range2.5–4.2V
Capacity32.5Ah
Energy121.9Wh
Mass790g
Est. cost$20
Cost / energy$164.1/kWh
Peak power density617W/kg
Continuous power density427W/kg
Cost / peak kW$41/kW
Cost / continuous kW$59.3/kW
Cycle life800–1500cycles

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

Voltage90.0V
Voltage range60.0–100.8V
Total energy17.6kWh
Cell mass113.8kg
Structure mass11.4kg
Cooling mass1.8kg
Total mass126.9kg
Cost$3,019
Cost / energy$172.0/kWh
Peak power density553W/kg
Continuous power density383W/kg
Cost / peak kW$43.0/kW
Cost / continuous kW$62.1/kW
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

Voltage630.0V
Voltage range420.0–705.6V
Total energy122.9kWh
Modules mass888.2kg
Structure mass147.4kg
Cooling mass49.1kg
Electrical mass20.0kg
Total mass1,104.8kg
Cost$21,811
Gravimetric density111.2Wh/kg
Cost / energy$177.5/kWh
Peak power density445W/kg
Continuous power density308W/kg
Cost / peak kW$44.4/kW
Cost / continuous kW$64.1/kW
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

Voltage630.0V
Total energy122.9kWh
Mass1,104.8kg
Cost$21,811
Pack density111.2Wh/kg
Cost / energy$177.5/kWh
Peak power density445W/kg
Continuous power density308W/kg
Cost / peak kW$44.4/kW
Cost / continuous kW$64.1/kW
Cell cycle life800–1500cycles

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

Upgrade your plan

Basic

Build from scratch

$10/month
  • Everything in Free
  • 10 commercial cells + custom cell
  • 7 commercial module presets
  • Save & compare configurations
Premium

Everything unlocked

Best value
$20/month
  • Everything in Basic
  • Full preset library
  • Liquid & immersion cooling
  • Risk panel + advanced analysis
  • Excel & PDF export
  • OEM / wholesale cost mode

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.