BYD ditches the module for pack-level cost savings in its Blade battery

June 15, 2020 | Case Study

For the past decade, battery electric vehicle (BEV) battery packs have been made the same way: Cells are grouped into modules, which are assembled into packs that go into the vehicle. Elon Musk noted that Tesla's early choice to use modules allowed for easier servicing, as failed modules could be swapped without changing an entire pack, but today, it also serves the role of providing additional protection against thermal or mechanical stress – which is crucial, as the pursuit of higher energy density and lower-cost cells meant accepting less stable chemistries. In an industry first, BYD announced a new pack technology called the "Blade Battery," in which the cells are directly assembled into the pack as a structural member. The first vehicle using this cell-to-pack design will be a flagship sedan called the Han, due to be released in the summer of 2020.