Geometric Scaling of Battery Cells and Its Effect on Key Performance Indicators

Tim de Krijger, Jorn van Kampen, Mouhriz Boulghalgh, Theo Hofman

This paper presents a computationally lightweight scaling model for cylindrical lithium-ion battery cells, intended for early-stage battery design-space exploration. The model maps selected geometric and electrode-level design variables, including cell height, cell diameter, cathode active loading, and cathode porosity, to cell-level performance indicators such as capacity, DC internal resistance, mass, volume, and winding length. The scaling model is validated against available cylindrical cell data by comparing predicted capacity, internal resistance, and winding length. The validated model is subsequently used in a single-cell design-space exploration and global sensitivity analysis to evaluate capacity, internal resistance, gravimetric energy density, and volumetric energy density. The results identify the dominant design variables, favourable parameter directions, and key trade-offs between cell geometry, electrode loading, resistance, and energy density. The proposed model provides a basis for future integration into higher-level battery system and vehicle optimization frameworks.