4680

4680 is a designation for a cylindrical lithium-ion battery cell format used in electric vehicles and energy storage systems. The numbers refer to a diameter of 46 millimeters and a height of 80 millimeters. The format was popularized by Tesla, which unveiled the 4680 cell at its Battery Day in 2020. The 4680 is larger than the prior 2170 cells and is notable for its tabless design, which reduces internal resistance and simplifies manufacturing.

The larger size enables higher energy density per cell and can contribute to lower pack costs when used in a modular, or even structural, battery pack where the cells contribute to the vehicle’s structural stiffness. Tesla and suppliers have highlighted potential improvements in thermal management and production efficiency, though large-scale manufacturing remains a challenge.

Applications include Tesla's electric vehicles, starting with the Model Y at certain production lines, and various long-term energy storage projects. As of the early 2020s, several automakers and battery manufacturers have explored the 4680 format, with multiple supply arrangements announced.

Challenges include scaling up production to meet demand, developing compatible manufacturing equipment, and ensuring material supply chains for nickel, lithium, copper, and other components. Performance and safety characteristics continue to be evaluated as production expands.

See also: lithium-ion battery formats, battery cell design.