--- title: "Lithium Prismatic Cells vs Cylindrical Cells: Pros and Cons" description: Prismatic vs cylindrical cells in lithium batteries have different qualities, capacity range, size and shape, and costs that affect the final application. image: https://blog.epectec.com/hubfs/blog/cylindrical-and-prismatic-battery-cells.jpg --- [![Epec Engineered Technologies](https://www.epectec.com/images/logo.png "Epec Engineered Technologies")](https://www.epectec.com/) [![Epec Engineered Technologies](https://www.epectec.com/images/logo.png "Epec Engineered Technologies")](https://www.epectec.com/) - [Articles](https://www.epectec.com/articles/) - [Blog](https://blog.epectec.com/) - [Webinars](https://www.epectec.com/webinar/) - [Videos](https://www.epectec.com/videos/) - [Case Studies](https://www.epectec.com/case-studies/) - [News & Events](https://www.epectec.com/news/) - [Customer Portal](https://system.netsuite.com/c.406760/site/NSlogin.html) - [About](https://www.epectec.com/about/overview/) - 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[Register](https://secure.epecpcb.com/epec/index2.jsp) [![](https://www.epectec.com/images/InstantPCBQuote-logo.png)](https://www.epectec.com/instantpcbquote/) [Login](https://secure.epecpcb.com/epec/) [Register](https://secure.epecpcb.com/epec/index2.jsp) Register to Quote and Order Your PCBs Fast, Easy & Online, 24/7 - [Home](https://www.epectec.com/) - [Blog](https://blog.epectec.com/) - Pros and Cons of Lithium Prismatic Cells vs Cylindrical Cells Share This Page: [LinkedIn](https://blog.epectec.com/#linkedin) [X](https://blog.epectec.com/#x) [Facebook](https://blog.epectec.com/#facebook) [Email](https://blog.epectec.com/#email) # Pros and Cons of Lithium Prismatic Cells vs Cylindrical Cells [![Anton Beck](https://blog.epectec.com/hubfs/Blog-Authors/anton-beck.jpg "Anton Beck")](https://blog.epectec.com/author/anton-beck) Written by [Anton Beck](https://blog.epectec.com/author/anton-beck) Posted on April 13, 2023 at 8:49 AM ![Anton Beck](https://blog.epectec.com/hubfs/Blog-Authors/anton-beck.jpg "Anton Beck") - [Tweet](https://twitter.com/share) [Battery-powered products](https://www.epectec.com/batteries/) come in a wide range of shapes, sizes, and performance requirements, which is why [lithium battery cells](https://www.epectec.com/batteries/custom-lithium-battery-packs.html) are manufactured in multiple form factors. Two of the most common are [prismatic cells and cylindrical cells](https://blog.epectec.com/pros-and-cons-of-lithium-prismatic-cells-vs-cylindrical-cells). Each offers advantages and limitations that can significantly affect battery pack design, performance, thermal behavior, manufacturing costs, and long-term reliability. Selecting the right cell format is not simply a matter of choosing the highest capacity or lowest cost. The form factor influences available power, mechanical integration, cooling requirements, certification considerations, and how the battery pack may respond if an individual cell fails. [![Free Ebook Download: Using Lithium Cells in Custom Battery Packs](https://no-cache.hubspot.com/cta/default/707152/36609474-182c-4048-a2b8-32e26e9f9bd9.png)](https://cta-redirect.hubspot.com/cta/redirect/707152/36609474-182c-4048-a2b8-32e26e9f9bd9) ![Example of cylindrical and prismatic battery cells](https://blog.epectec.com/hs-fs/hubfs/blog/cylindrical-and-prismatic-battery-cells.jpg?width=800&height=400&name=cylindrical-and-prismatic-battery-cells.jpg) *Example of cylindrical and prismatic battery cells.* ## Battery Cell Shapes and Physical Construction ### Cylindrical Cells Cylindrical cells are long, round cells similar in appearance to the batteries commonly used in consumer electronics. Internally, the electrodes are tightly wound and enclosed within a metal can. Cylindrical cells are among the most widely used battery formats and are available in standardized sizes, including: - 14650 - 18650 - 21700 - 26500 The round geometry helps distribute internal pressure and electrolyte more evenly throughout the cell. As a result, cylindrical cells are generally less susceptible to leakage, bloating, or deformation. Because they are available in standardized formats from multiple manufacturers, cylindrical cells are often easier to source and integrate into production programs. ### Prismatic Cells [Prismatic cells](https://www.epectec.com/batteries/lithium-prismatic-cells.htm) use a flat, rectangular design. Internal components are arranged in layered stacks and enclosed in steel or aluminum housings. An insulated film covers the exterior of the can. The rectangular shape makes prismatic cells attractive when maximizing available space is a design priority. They are commonly used in electric and hybrid vehicles where efficient packaging is important. Unlike cylindrical cells, prismatic cells do not follow universal size standards. Manufacturers often develop application-specific dimensions, resulting in a wide variety of cell sizes and configurations. Because many prismatic cells are effectively custom products, customers should consider minimum order quantities, sourcing requirements, and certification planning early in the design process. ## Mechanical Considerations and Cell Durability The geometry of each cell type affects how it responds to mechanical stress. The corners of prismatic cells can be more vulnerable to shocks and vibration if not properly protected within the [battery enclosure](https://www.epectec.com/batteries/battery-enclosure-design.html). These corner regions may experience greater stress concentrations during operation. In addition, the rectangular shape can create challenges for electrolyte distribution, potentially contributing to cell bloating or deformation under certain conditions. Cylindrical cells do not have these corner-related concerns and benefit from a shape that naturally distributes internal stresses more uniformly. ## Capacity and Voltage Considerations Prismatic and cylindrical cells differ significantly in how capacity and voltage are achieved within a battery pack. Because prismatic cells are physically larger and require fewer interconnections within the pack, they can provide higher individual cell capacities. For example, one lithium phosphate battery (LiFePO4) prismatic cell may provide 3.2 volts and 100Ah. Cylindrical cells are smaller and store less energy per cell. Achieving equivalent pack capacity generally requires a larger number of cells and connections. - Approximately 18 cylindrical cells are required to achieve the same amp-hour capacity as one prismatic cell. - To reach 48 volts, a battery system would require 18 prismatic cells or 16 groups of 18 cylindrical cells. While cylindrical cells typically require more cells to achieve comparable capacity, they provide greater voltage and faster discharge rates per amp-hour (Ah). ## Which Cell Type Is Better for Different Applications? Neither form factor is universally better than the other. The optimal choice depends on application priorities. **Prismatic cells are often favored when:** - High capacity is required - Packaging efficiency is critical - Space utilization within the product is a primary concern **Cylindrical cells are often preferred when:** - Higher discharge performance is needed - Thermal management is important - Cost-effective large-scale manufacturing is a priority - Long-term sourcing flexibility is desired Cylindrical cells are a common choice for high-performance applications such as toys and electronics, while prismatic cells are better suited for energy-intensive applications including storage systems, [medical devices](https://www.epectec.com/batteries/battery-packs-for-medical-devices.html), and vehicles. ## Battery Pack Construction and Thermal Management Cell geometry also affects how individual cells are assembled into a battery pack. ### Cylindrical Cell Pack Design Cylindrical cells are typically arranged in multiple [series and parallel configurations](https://www.epectec.com/batteries/battery-configuration.html). Depending on available space, a pack may use layouts such as: - Three rows of four cells - Four rows of three cells The gaps between round cells create airflow paths that help dissipate heat. This natural spacing improves temperature control and allows heat to escape more efficiently during operation. ### Prismatic Cell Pack Design Prismatic cells are commonly assembled in series configurations. Because the flat cell walls sit directly against adjacent cells, airflow between cells is limited. Heat is therefore transferred through the cell walls from one cell to the next rather than being dissipated through open airflow channels. As a result, prismatic cells generally do not release heat as quickly as cylindrical cell assemblies. ## Lifecycle and Cell Failure Considerations Battery lifecycle and pack-level reliability can differ substantially between the two formats. - Typical prismatic cells average approximately 2,000 cycles. - Cylindrical cells typically range from 300 to 500 cycles. The effect of a failed cell can also vary depending on pack architecture. In cylindrical battery packs, the larger number of interconnected cells can reduce the impact of a single failed cell. The pack may continue providing power because capacity is determined by the lowest-capacity cell group. In prismatic-cell battery packs, a failed cell may have a greater impact on the overall battery pack because of the way cells are connected in series. ## Testing and Certification Requirements Regardless of form factor, battery packs should be tested according to: - Cell chemistry requirements - Industry requirements - Customer specifications [Testing](https://www.epectec.com/batteries/united-nations-testing.html) and [certification](https://www.epectec.com/batteries/battery-pack-certifications.html) are commonly required for lithium battery chemistries in both cylindrical and prismatic cell designs. When custom prismatic cells are used, certification planning becomes particularly important. Cells typically require UL and UN 38.3 certification for safety and [transportation requirements](https://www.epectec.com/batteries/battery-transportation-requirements.html). Manufacturers generally manage ongoing certification maintenance for high-volume customers. However, projects near minimum-order thresholds should verify that certifications remain active over time. If production intervals become extended, certification renewals may require additional planning and costs. ## Manufacturing Costs and Supply Considerations Cost differences between the two cell formats are driven by manufacturing processes, production volumes, and sourcing requirements. Cylindrical cells are generally less expensive to manufacture because production technologies have been established for many years and support efficient mass production. **Prismatic cells may carry higher costs due to:** - Larger cell sizes - Custom cell development - Lower production volumes - Minimum order quantity requirements [Battery chemistry](https://www.epectec.com/batteries/chemistry/) can also influence overall costs. Lithium battery chemistries may have higher testing and certification expenses than certain nickel-based chemistries. One frequently overlooked consideration is product availability. Although prismatic cells are available in many sizes, they are often not off-the-shelf products. Small production quantities and prototype samples may be difficult to obtain because manufacturers frequently require minimum production volumes to justify a manufacturing run. For projects requiring fewer than 5,000 pieces, it is important to confirm which cell sizes the supplier regularly manufactures and whether sample cells will differ from full production units. ## Choosing Between Prismatic and Cylindrical Cells Cell selection should be based on the application's electrical, mechanical, thermal, lifecycle, and cost requirements. **Prismatic cells offer:** - Higher individual cell capacity - Efficient space utilization - Fewer pack interconnections **Cylindrical cells offer:** - Lower manufacturing costs - Better thermal management - Standardized cell formats - Reduced susceptibility to bloating, leakage, and rupture The best choice depends on the balance between capacity requirements, performance expectations, lifecycle goals, packaging constraints, certification needs, and overall budget. ## Summary Prismatic and cylindrical lithium cells each present unique advantages and tradeoffs for battery pack designers. Prismatic cells provide higher capacity and efficient use of available space, making them well suited for energy-intensive applications. Cylindrical cells, by contrast, offer standardized sizing, lower manufacturing costs, improved thermal management, and broader availability. Evaluating capacity requirements, thermal performance, lifecycle expectations, certification obligations, and sourcing constraints early in the design process helps ensure the selected cell format aligns with the application's long-term performance and production goals. --- ## Key Takeaways - **Shape and Size Differences:** Cylindrical cells are round and compact, commonly used in everyday electronics, while prismatic cells are flat and rectangular, ideal for space-efficient applications like electric vehicles. - **Voltage and Capacity Considerations:** Prismatic cells have higher capacity due to their larger size, while cylindrical cells provide better energy efficiency and faster discharge rates, making them suitable for high-performance applications. - **Thermal Management and Lifespan:** Cylindrical cells dissipate heat more efficiently due to airflow between cells, whereas prismatic cells retain heat, which can impact performance and lifespan. - **Manufacturing Costs and Availability:** Cylindrical cells are easier and cheaper to mass-produce, while prismatic cells may require custom manufacturing with minimum order quantities, increasing costs. - **Testing and Certification Requirements:** Prismatic cells often require additional certifications like UL and UN38.3, which may need yearly updates, whereas cylindrical cells typically have well-established certification processes. - [Tweet](https://twitter.com/share) Topics: [Battery Packs](https://blog.epectec.com/topic/battery-packs) --- [Next](https://blog.epectec.com/overview-of-via-holes-in-flexible-circuit-boards-designs) | [All posts](https://blog.epectec.com/all) | [Previous](https://blog.epectec.com/what-is-un38-3-testing-and-why-is-it-necessary) [![New Call-to-action](https://no-cache.hubspot.com/cta/default/707152/c0752b9b-6c31-42d7-8b25-4b0ca6cc72c5.png)](https://cta-redirect.hubspot.com/cta/redirect/707152/c0752b9b-6c31-42d7-8b25-4b0ca6cc72c5) ## Leave a Comment --- ## Related Posts --- ### Recent Posts --- ### Posts by Topic - [Printed Circuit Boards (161)](https://blog.epectec.com/topic/printed-circuit-boards) - [Product Design (138)](https://blog.epectec.com/topic/product-design) - [Battery Packs (121)](https://blog.epectec.com/topic/battery-packs) - [Cable Assemblies (102)](https://blog.epectec.com/topic/cable-assemblies) - [Flex & Rigid-Flex PCB's (95)](https://blog.epectec.com/topic/flex-rigid-flex-pcbs) - [Electronics Industry (61)](https://blog.epectec.com/topic/electronics-industry) - [User Interfaces (55)](https://blog.epectec.com/topic/user-interfaces) - [Quality Solutions (33)](https://blog.epectec.com/topic/quality-solutions) - [Flexible Heaters (30)](https://blog.epectec.com/topic/flexible-heaters) - [Events, Training, and Support (9)](https://blog.epectec.com/topic/events-training-and-support) - [RF Products (7)](https://blog.epectec.com/topic/rf-products) - [CNC Machining (3)](https://blog.epectec.com/topic/cnc-machining) - [Fans & Motors (1)](https://blog.epectec.com/topic/fans-motors) See All --- --- ### Need Help with A Project? 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