Engineering Tool BETA

Upgrade and downsize your battery pack with PCC batteries
Variable Pack Volume + Optimized Cell Dimensions + Cell Format Comparison

Zippy lets you define any pack envelope. Enter your dimensions below and all calculations update dynamically.

Typical E-motorcycle Pack Volume: 363 Γ— 209 Γ— 149 mm
Pack Volume (L): 11.30 L
Target Voltage: 51–58 V (NMC)
Pack Envelope β€” define your pack dimensions. All calculations update live.
β†’ 11.27 L total
Cell Parameters
Pack Volume Budget
Full: 11.27 L β†’ 9.58 L available
% reserved for BMS, bus bars, thermal management
✦ Recommended Dims
Computing...
Optimized for max capacity at 51–58 V target
Active Chemistry
NMC
Cell Dimensions
Cell Electrical
Electrode Stack (per unit cell)
Physical
Pack Target
Pack Configuration
β€”
Total Cells
β€”
β€”
Pack Voltage
β€”
Pack Capacity
β€”
Cell Stack Model
Stacked Unit Cells
β€”
185Β΅m/unit cell
Derived Cell Capacity
β€”
mAh/layer Γ— layers
Energy & Density
Energy
β€”
Volumetric Density
β€”
Gravimetric
β€”
Physical
Pack Weight
β€”
Volume Utilization
β€”
Cells Fit (Max)
β€”
β€”
Active Vol Fraction
β€”
pack-level Β· excl. overhead
Cell Weight (calc)
β€”
cathode+anode+sep+CC+electrolyte+case
Al Casing Weight
β€”
estimated Al can mass
2D Cell Diagram β€” Individual Cell
Cell Layout
50 mm
Cell
Gap
Unused
Volume Utilization β€”
Cell Parameters
Pack Volume Budget
Full: 11.27 L β†’ 9.02 L available
% reserved for bus bars, wiring harness, thermal management
✦ Recommended Dims
Computing...
Optimized diameter Γ— height for max capacity at 51–58 V target
Active Chemistry
NMC
Cell Format
Cell Electrical
Physical
Pack Target
Best Orientation (auto)
Calculating...
Pack Configuration
β€”
Total Cells
β€”
β€”
Pack Voltage
β€”
Pack Capacity
β€”
Jelly Roll Model
Electrode Area
β€”
jelly roll vol Γ· 185Β΅m/bilayer
Derived Cell Capacity
β€”
mAh/cmΒ² Γ— area
Energy & Density
Energy
β€”
Volumetric Density
β€”
Gravimetric
β€”
Physical
Pack Weight
β€”
Volume Utilization
β€”
Hex Packing
β€”
β€”
Active Vol Fraction
β€”
pack-level Β· excl. overhead
Al Can Weight
β€”
estimated Al can + caps
2D Cell Diagram β€” Individual Cell
Cell Layout
50 mm
Cell
Interstitial
Unused
Hex Pack Efficiency β€”
PCC Parameters
Pack Volume Budget
Full: 11.27 L β†’ 10.37 L available
% reserved β€” PCC inherently safe: minimal thermal mgmt needed
✦ Recommended Dims
Computing...
Optimized X Γ— Y for max capacity at 51–58 V target (8% overhead)
Mono-cell Voltage
3.7V NMC
Sub-Stack Footprint
Electrode Stack (per mono-cell)
Pack Target
⟑ PCC Advantages
Any Shape Cells conform to pack geometry β€” no wasted corners
Metal-Free C-Polymer replaces Cu/Al β€” 88% lighter current collectors
No Tabs Needed Bipolar stack β€” current flows axially, no parallel tab welding
Inherently Safe Non-conductive polymer β€” no internal short circuit propagation
No Rigid Casing Zero aluminum housing β€” 100% of cell volume is active electrode material vs ~92–96% for prismatic/cylindrical
Stack Architecture
β€”
Mono-cells/Stack
β€”
β€”
Parallel Sub-Stacks
β€”
β€”
Sub-Stack Dims
β€”
Pack Output
Pack Voltage
β€”
Pack Capacity
β€”
Energy
β€”
Density & Weight Advantage
Volumetric Density
β€”
Vol. Utilization
β€”
vs ~85% prismatic
Pack Weight
β€”
Cost Savings vs Metal Current Collectors
*CC Cost (Cu + Al foil)
β€”
*CC Cost (PCC)
β€”
Savings / Pack
β€”
β€”
2D Cell Diagram β€” PCC Sub-Stack Footprint
Stack Layout
50 mm
Cathode
Anode
PCC Layer
Separator
Volume Fill β€”
Visual Comparison β€” Same Pack Volume, Same Scale
β–ͺ Prismatic
Vol. Utilβ€”
Energyβ€”
● Cylindrical
Vol. Utilβ€”
Energyβ€”
β—† PCC (Kavian)
Vol. Utilβ€”
Energyβ€”
Interactive 3D Pack Comparison β€” Same Scale, Full Layout
β–ͺ Prismatic
● Cylindrical
β—† PCC (Kavian)
Live Metrics β€” NMC 811 β€” All 3 Configs
Metric β–ͺ Prismatic ● Cylindrical β—† PCC (Kavian) BEST PCC vs Prismatic PCC vs Cylindrical
Energy (kWh) β€” β€” β€” β€” β€”
Pack Voltage (V) β€” β€” β€”
Pack Capacity (Ah) β€” β€” β€” β€” β€”
Volumetric Density (Wh/L)
excl. overhead ↓		 β€”
β€”		 β€”
β€”		 β€”
β€”		 β€” β€”
Gravimetric Density (Wh/kg) β€” β€” β€” β€” β€”
Pack Weight (kg) β€” β€” β€” β€” β€”
Volume Utilization (%)
excl. overhead ↓		 β€”
β€”		 β€”
β€”		 β€”
β€”
Active Vol Fraction (%)
excl. overhead ↓		 β€”
β€”		 β€”
β€”		 β€”
β€”
Cell Count β€” β€” β€”
*CC Cost / Pack (est.) β€” β€” β€”
*CC Cost / kWh
$/kWh Β· pack level Β· key sales metric		 β€” β€” β€” β€” β€”
β—† PCC Performance Summary
Calculating…
*CC β€” Current Collectors (Cu foil anode + Al foil cathode; cost derived from foil thickness Γ— material density Γ— $/kg)

Kavian Dry-Process Electrodes

Interested in these results for your pack design?

Contact Sakuu's team to discuss how PCC technology can meet your energy density and cost targets.