<2025> 4680 Battery Technology Development Trend and Outlook
The 4680 battery is a large cylindrical lithium-ion cell with a diameter of 46 mm and a length of 80 mm. Since Tesla first unveiled it at its 2020 Battery Day, it has emerged as a symbolic cell form factor leading technological innovation across the global battery and electric vehicle industries. Compared to the existing 2170 and 1865 formats, the 4680 highlights multidimensional advantages such as higher energy density, reduced cell assembly count, improved thermal management efficiency, and lower costs.
Accordingly, not only Tesla but also major cell manufacturers including Panasonic, LG Energy Solution, Samsung SDI, CATL, and EVE Energy are racing to secure 4680 production capacity.
The 4680 battery particularly enables enhanced structural efficiency of EV platforms through Cell-to-Chassis (CtC) design and incorporates innovations such as the tabless electrode structure, which makes it possible to achieve high charge/discharge performance. These advances position the 4680 as a key technology that can drastically improve EV efficiency and cost competitiveness.
The most distinctive feature of the 4680, the tabless electrode structure, distributes the current-collecting tabs across the entire electrode instead of placing them at the cell’s edges. This leads to more uniform current flow, reducing resistance distribution, suppressing heat generation, and improving thermal diffusion efficiency, thereby preventing localized overheating under high-power conditions. Additionally, the simplified manufacturing process eliminates the need for electrode-tab connection steps, boosting yield. While this architecture is difficult to implement in pouch or prismatic cells, in cylindrical cells—especially large ones—its advantages are maximized. Tesla’s in-house cells actively leverage this structure along with dry electrode coating.
Meanwhile, Tesla sought to apply the dry electrode coating technology introduced via its acquisition of Maxwell Technologies to the 4680. This method, which attaches solid electrode materials to the current collector by high-speed pressing without using solvents, is an environmentally friendly (NMP-free) process. It shortens production time by eliminating drying, allows thicker and denser electrodes, and thereby improves energy density. However, challenges remain in mass production, such as ensuring coating thickness uniformity and interfacial adhesion stability. Some companies are therefore developing alternative high-speed coating solutions based on wet processes.
To maximize energy density, high-energy active materials are being applied: cathodes employ high-nickel (Ni > 88%) NCM/NCA to enhance both density and lifespan; anodes use silicon-composite graphite (Si-C) or fully silicon-based designs to boost fast-charging capability; electrolytes incorporate high-voltage stabilizing additives or gel electrolytes to improve durability and stability. In particular, silicon anodes face expansion control and conductivity challenges, tackled by nanocomposite technologies, carbon-matrix architectures, and interfacial stabilization additives.
As capacity increases, so does the need for thermal runaway and safety countermeasures. Due to the large-cell nature of the 4680, a single-cell failure can quickly cascade across the module. Accordingly, safety technologies such as thermal barriers, built-in PTC/thermal fuses, flame-retardant cell casings, and dispersed cooling pathways are being developed. Since structural analysis becomes more complex than in pouch or prismatic cells, simulation-based integrated structural–thermal–electrical design is expanding.
Although Tesla pioneered the concept, development of 46Φ large-format cells is now actively underway in Korea, Japan, and China. Tesla is mass-producing 4680 cells at its Texas Gigafactory and Berlin plant, surpassing 100 million units in 2024. The company has applied the second-generation “Cybercell” to the Cybertruck to improve charging speed and performance, and by 2026 plans to develop at least four new variants—including the NC05—based on dry coating. Panasonic is conducting pilot production and supply from its Wakayama (Japan) and Nevada (U.S.) facilities, and has completed renovations for a large 4680 plant in Kansas. It is also undergoing sampling and approval processes with OEMs beyond Tesla.
Among Korean “K-3” companies: LG Energy Solution began pilot production at Ochang in August 2024 and is preparing for mass production at its new Arizona plant by the first half of 2026. Samsung SDI, starting in Q1 2025, will apply 46Φ cells in micromobility packs and expand adoption with European OEMs such as BMW. Meanwhile, Chinese companies including CATL and EVE are testing 46-series cells for structural compatibility, while BYD is developing similar large cells based on LFP chemistry.
Ultimately, while the 4680 holds strong potential in terms of high capacity, high density, and cost reduction, the keys remain mass-production stabilization and technological maturity. The period between 2025 and 2026 is expected to be a watershed, as Tesla and Panasonic accumulate production experience while Korean firms build out full-scale supply systems.
Competition, however, is diversifying. Rivalry with other battery technologies such as LFP, the completion of dry processes, yield improvements, and levels of localization will shape the industry landscape. For the 4680 to truly establish itself as a game-changer in the EV market, the trifecta of technical completeness, cost competitiveness, and supply chain stability must be achieved.
This report by SNE systematically compiles scattered data from corporate announcements, teardown studies, and performance tests related to the 4680. It also reviews key academic papers to assess the actual effectiveness and performance improvements of the 4680, summarizes the status and main products of manufacturers, and presents correlations between Gigafactory scale, Cybertruck production volumes, and cell output—providing valuable insights on manufacturability for researchers and stakeholders.
The strong points of this report are as follows:
① Comprehensive consolidation of development trends and information on the 4680, enabling easy overall understanding
② Detailed analysis of 4680 cell and pack teardown reports, enhancing comprehension
③ Market and production outlook analysis for the 4680, clarifying market size and growth rates
④ In-depth review of materials and technologies applied in the 4680, based on academic papers
(a)(c) The total cost is classified into material costs, labor costs, depreciation, capital costs, energy costs, plant area costs, and other expenses, with their respective proportions shown. Material cost accounts for the largest share (72.0%).
(b)(d) Detailed material cost analysis of 2170 cells vs. 4680 cells. This donut chart breaks down material costs into anode, cathode, separator, electrolyte, and housing. It clearly shows that cathode and anode materials are the main cost drivers.
Manufacturing process of large tabless cylindrical lithium-ion cells (including can and end cap).
This figure visually illustrates the key steps of cell manufacturing:
Top left: Tabless jelly-roll fabrication (A1) – shows how the jelly roll is formed together with the current collector plate. Laser welding is indicated.
Top right: Can deep drawing (steel) or impact extrusion (aluminum) (A2) – illustrates the process of forming the housing.
Center: Cell assembly (B) – the jelly roll is inserted into the housing and assembled through various welding processes. Laser and ultrasonic welding are indicated.
Bottom: Finishing (C) – the fully assembled cell undergoes final inspection and treatment.
Table of Contents
1. Overview of 4680 Cylindrical Battery 15
1.1. Summary and Key Findings of Tesla Battery Day (Sep 22, 2020) 17
1.2. Battery Cell Design 17
1.3. Battery Cell Manufacturing Process 18
1.3.1. Coating Process 20
1.3.2. Winding Process 20
1.3.3. Assembly Process 20
1.3.4. Formation Process 20
1.4. Silicon Anode Material 21
1.5. High-Nickel Cathode Material 21
1.6. Cell-to-Vehicle Integration 22
1.7. Battery Cost Reduction 23
1.8. 4680 Battery Development 23
1.8.1. Specifications of 4680 Battery 24
1.8.2. Tesla Battery Suppliers 25
1.8.3. Global Development and Production Status of 4680 Batteries 26
1.9. Global 46xx Battery Production Capacity 27
1.9.1. Advantages and Disadvantages of New 46xx Cell Design 28
2. Development of 4680 Battery Cells 32
2.1. Cost Reduction and Efficiency Enhancement Strategy 32
2.2. Increasing Safety Requirements (Thermal Management Upgrade) 33
2.3. Fast Charging as a Future Trend: Advantages of 4680’s High Charging Speed 36
2.4. Market Entry Competition Among Leading Companies 36
2.5. Detailed Specifications of 46xx Batteries by Company 37
3. Detailed Technology of 4680 Battery 44
3.1. Cathode Materials 44
3.1.1. Ultra High-Nickel Application 44
3.1.2. Production Capacity Expansion 46
3.1.3. Manufacturing Technology Upgrade 47
3.2. Anode Materials 48
3.2.1. Silicon-Based Development 48
3.2.2. Silicon Development Timeline 49
3.2.3. Silicon Anode Modifications: Nanostructuring, Carbon Composites, Pre-lithiation 53
3.2.4. Commercialization Acceleration of Silicon Anode 59
3.3. Other Battery Materials 61
3.3.1. SWCNT Conductive Additives 62
3.3.2. Steel Battery Can 67
3.3.3. Aluminum Battery Can 71
3.3.3.1. Al Housing Cell Design Concept 76
3.3.3.2. 46xx Large Cylindrical Cell 78
3.3.3.3. 46xx Jelly Roll Concept 79
3.3.3.4. Jelly Roll Thermal Transfer and Distribution 79
3.3.3.5. Thermal Simulation of Jelly Roll Concept 80
3.3.3.6. Cooling Performance Enhancement for 46xx Cells 81
3.4. Improvements in 4680 Manufacturing Process 83
3.4.1. Process Technologies for 4680 83
3.4.2. Differentiation in Production Process 85
3.4.2.1. Dry Electrode Coating 85
3.4.2.2. Example Dry Process (Huaqi New Energy) 88
3.4.2.3. Integrated Electrode and Tab Cutting 89
3.4.2.4. Increased Laser Welding Difficulty 91
3.4.2.5. Integrated Die Casting and CTC 95
4. 4680 Battery Teardown and Analysis 100
4.1. Overview 100
4.2. Teardown and Analytical Process 101
4.3. Detailed Engineering Analysis of Tesla 4680 Cells and Packs 110
4.3.1. Tesla 4680 Cell Design Data (w/o Tab) 110
4.3.2. Pack Structure (Cell Orientation) 120
4.3.3. Proposed Assembly Methods for 4680 Pack 121
4.3.4. Analysis of 4680 Pack for Model 3: Expected Charge Time, Power, and Dimensions 122
4.3.4.1. Summary of Pack Analysis 122
4.3.4.2. Thermal Dissipation Discussion 125
4.3.5. Current Collector for Model 3 Battery 127
5. Teardown and Electrochemical Study of Tesla 4680 Cell 131
5.1. Summary 131
5.2. Study Overview 131
5.3. Previous Research 133
5.4. Detailed Analysis 133
5.5. Experiments 134
5.5.1. Overview of Test Cell 134
5.5.2. Cell Disassembly and Material Extraction 134
5.5.3. Structural and Elemental Analysis 138
5.5.4. Three-Electrode Analysis 139
5.5.5. Electrical Characteristics 140
5.5.6. Thermal Investigation 140
5.6. Results & Discussion 141
5.6.1. Cell and Jelly Roll Structure 141
5.6.2. Electrode Design 143
5.6.3. Material Properties 145
5.6.4. Three-Electrode Analysis 148
5.6.5. Capacity and Impedance Analysis 150
5.6.6. Quasi-OCV, DVA and ICA 151
5.6.7. HPPC (Hybrid Pulse Power Characterization) 152
5.6.8. Thermal Characterization at Cell Level 153
5.7. Conclusion 156
6. Technologies Required for 4680 Battery Success 157
6.1. Multi-Tab Technology 157
6.2. Tab Welding Technology 165
6.3. Cathode & Anode Materials 166
6.4. Cooling Technology 169
7. Comparison of 4680 with 18650 & 2170: Energy Density and Cost Reduction 175
7.1. Overview 175
7.2. 4680: Energy Density, Fast Charging, and Cost Reduction 176
7.2.1. Energy Density vs. Blade & Prismatic Hi-Ni Batteries 176
7.2.2. Improvement in Fast Charging Speed 178
7.2.3. Dry Electrode: Production Standardization and Cost Down 180
7.3. Use of High-Concentration Electrolyte 182
7.3.1. Electrolyte Reduction per GWh 182
7.3.2. High-Concentration Electrolyte with LiFSI Additive 186
7.3.3. Fluorinated Solvent (FEC): Performance Boost in NCM811/SiOx 190
7.4. Major Electrolyte Companies for 4680 192
8. Design of Battery Thermal Management System (BTMS) for Tesla 4680 Module 194
8.1. Introduction 194
8.2. Need for BTMS in EV Batteries 194
8.3. Cooling Methods 195
8.4. Literature Review 196
8.5. Liquid Cooling + Heat Pipe for 4680 Module: Method, Results, Conclusion 198
8.6. Thermal Analysis of Proposed Cooling System 202
8.7. Results & Discussion 205
8.8. Conclusion 207
9. Thermal Management of 4680 Cells: Design and Cooling 208
9.1. Overview 208
9.2. Introduction 208
9.2.1. Previous Research 209
9.2.2. Contributions of This Study 210
9.3. Experimental 210
9.3.1. Reference Cell 210
9.3.2. Thermal Battery Test Bench 211
9.3.3. Test Procedure 212
9.4. Simulation Model 212
9.4.1. Housing & Cooler 213
9.4.2. Jelly Roll 213
9.4.3. Cathode and Anode Tabs 214
9.4.4. Model Calibration and Validation 214
9.5. Simulation Results 216
9.5.1. Impact of Tab Design 216
9.5.2. Impact of Housing Materials 218
9.5.3. Interaction between Tab Design and Housing Material 219
9.6. Conclusion 221
10. Design, Properties, and Manufacturing of Cylindrical LIB Cells 222
10.1. Overview 222
10.2. Experimental Materials and Methods 223
10.2.1. Cell Design 223
10.2.2. Cell Properties 225
10.3. Experimental Results and Discussion 226
10.3.1. Design of Cylindrical LIB Cell 226
10.3.2. Jelly Roll Design 228
10.3.2.1. Geometry 228
10.3.3. Tab Design 229
10.3.4. Cell Characteristics 232
10.3.4.1. Energy Density 232
10.3.4.2. Cell Resistance 232
10.3.4.3. Thermal Behavior 234
10.3.5. Jelly Roll Manufacturing 236
10.4. Conclusion 239
11. Effects of Cell Size and Housing Materials in Tabless Cylindrical LIB Cells 241
11.1. Overview 241
11.2. Experiment 242
11.2.1. Reference Cell 242
11.2.2. Modeling 243
11.2.2.1. Geometrical Modeling 243
11.2.2.2. Jelly Roll Electrode Layers 243
11.2.2.3. Hollow Core 244
11.2.2.4. Tabless Design 244
11.2.3. Cell Housing 245
11.2.4. Thermo-Electrochemical Framework 246
11.2.4.1. Boundary Conditions and Discretization 247
11.3. Results and Discussion 247
11.3.1. Energy Density 247
11.3.1.1. Effect of Diameter 247
11.3.1.2. Effect of Height 248
11.3.1.3. Effect of Housing Material 248
11.3.2. Fast Charging Performance 249
11.3.2.1. Heat Transfer Algorithm 249
11.3.2.2. Effect of Axial Cooling (Height/Housing) 250
11.3.2.3. Effect of Axial Cooling (Diameter/Housing) 253
11.3.2.4. Tab Design & Series Resistance Scaling 256
11.3.2.5. Overall Effect on Fast Charging 259
11.4. Conclusion 260
12. Thermal Runaway & Propagation in Large Tabless Cylindrical LIB Cells 261
12.1. Study on TR & TP Characteristics 261
12.2. Introduction: Need for New Design 262
12.2.1. Test Cell & Innovations 262
12.2.2. Limitations of Al Housing 263
12.2.3. TR Test Methods 264
12.2.4. Potting Compounds 265
12.2.5. Future Research 265
12.3. Experiment 265
12.3.1. Tabless Cell Investigation 265
12.3.2. Trigger Methods in Al Housing 267
12.3.2.1. China Safety Standards 267
12.3.2.2. FTRC Comparison 267
12.3.2.3. Large Cell Triggering Limits 268
12.3.2.4. Rupture Mechanism & Short Circuit 268
12.3.2.5. Axial Nail Penetration 269
12.3.2.6. Trigger Parameters & Geometry 269
12.3.2.7. Accelerated Calorimetry (EV-ARC) 270
12.3.2.8. Pressure Chamber Bench 270
12.3.2.9. Small Module TP Test 271
12.3.2.10. Radial Nail & Plate Test 272
12.3.2.11. Mechanical Triggering 272
12.3.3. EV-ARC Evaluation 272
12.3.3.1. Decomposition & Detection Temp 272
12.3.3.2. Reaction Mechanism 273
12.3.3.3. Dispersion Analysis 273
12.3.3.4. Temperature Distribution 273
12.3.3.5. Enthalpy Estimation 274
12.3.3.6. Voltage & Venting 275
12.3.3.7. Post-TR Mass Mapping 276
12.3.3.8. TR Cell Characteristics 278
13. Comparative Analysis: Tesla 4680 vs. BYD Blade Cell 282
13.1. Introduction 282
13.2. Results & Discussion 283
13.2.1. Mechanical Design & Process 283
13.2.2. Cell Housing 284
13.2.3. Electrode Composition 285
13.2.4. Contact Technology 287
13.2.5. Electrode Structure & Measurement 288
13.2.6. Manufacturing Process Flow 289
13.2.7. Materials & Cost Analysis 290
13.2.8. Electrical Performance 292
13.2.9. Thermal Efficiency & Resistance 292
13.2.10. Thermal Analysis 293
14. Modeling Study: Cell Size & Housing Impact in Tabless Cylindrical LIB 295
14.1. Introduction 295
14.2. Process Analysis 295
14.2.1. Manufacturing Impact 295
14.2.2. Reference Cell 296
14.2.3. Manufacturing Classification 296
14.2.3.1. Tabless Jelly Roll 298
14.2.3.2. Housing 298
14.2.3.3. Assembly 299
14.3. Modeling 301
14.3.1. Process-Based Cost Model 301
14.3.2. Geometrical Model 301
14.3.3. Process Model 302
14.3.4. Operations Model 306
14.3.5. Financial Model 306
14.4. Results & Discussion 307
14.4.1. Validation 307
14.4.2. Cell Size Effects 309
14.4.2.1. Diameter 309
14.4.2.2. Height 311
14.4.2.3. Cell Count 313
14.4.3. Housing Material Effects 315
14.5. Conclusion 316
15. Cost Comparison: Tabless vs. Standard Electrode Cylindrical LIB 317
15.1. Summary: Tesla's Tabless Design 317
15.2. Introduction 318
15.2.1. Design Comparison & Process Considerations 319
15.3. Methodology 324
15.3.1. Cost Modeling 324
15.3.2. Included Elements 325
15.3.3. Parameterization 326
15.4. Results 328
15.4.1. Output Calculation 328
15.4.2. Baseline Cost Analysis 330
15.4.3. Sensitivity Analysis 332
15.5. Conclusion 334
16. Status of 4680 Cell Manufacturers 335
16.1. Tesla 335
16.2. Panasonic 337
16.3. LGES 341
16.4. Samsung SDI 343
16.5. SK On 347
16.6. EVE 349
16.7. BAK 357
16.8. CATL 361
16.9. Gotion Hi-TECH 363
16.10. SVOLT 368
16.11. CALB 369
16.12. Envision AESC 373
16.13. LISHEN 375
16.14. Easpring (Dangsheng Technology) 380
16.15. Kumyang 382
16.16. BMW 387
16.17. Dongwon Systems 394
16.18. Sungwoo 396
16.19. TCC Steel 399
16.20. Dongkuk Industries 402
16.21. Shinheung SEC 406
16.22. Sangsin EDP 407
16.23. LT Precision 410
16.24. NIO 410
17. Patent Analysis on 4680 Batteries 413
17.1. Battery with Tabless Electrode 413
17.2. Tesla: Tabless Energy Storage Devices and Manufacturing Methods 416
17.3. Tesla Dry Electrode Process Patent (1): Fine Particle Non-Fibrous Binder 425
17.4. Tesla Dry Electrode Process Patent (2): Adhesive Passivation Film Composition for Dry Electrodes 429
17.5. LG Energy Solution: Tabless-Related Patents (Electrode Assembly, Battery, Battery Pack, and Vehicle) 432
17.6. Murata: Tabless Battery 443
17.7. Jiangsu Zenergy Battery 451
17.8. EVE Energy (Tab Flattening Device) 456
17.9. Microvast Inc. (Tab Plate & Wound Battery) 461
18. Market Outlook for 4680 Batteries 465
18.1. Overall Market Outlook 465
18.2. Materials and Process Technology Forecast for 4680 468
18.3. Chemical Industry: Silicon-Carbon Anode, PTFE, LiFSI, and Other Materials 470
18.3.1. Silicon-Carbon Anode Materials 470
18.3.2. PTFE, LiFSI, and Other Additives 471
18.3.3. Non-Ferrous Metals: Lithium, Cobalt, Nickel Demand 471
18.3.4. Hi-Ni Cathode + Silicon-Based Anode 475
18.4. Policy, Demand, and CAPA Forecasts Surrounding 4680 476
18.4.1. 4680 Cylindrical Battery Industry Chain 477
18.4.2. Analysis of China’s 4680 Battery Industry Status 478
18.4.3. Market Structure of 4680 Cylindrical Batteries 479
18.4.4. Declining Trend in Cylindrical Battery Adoption 481
18.4.5. New Form Factor Development by Battery Manufacturers 484
18.4.6. Development and Production Forecast for 4680 (46xxx) Batteries 485
18.4.7. Development Trend of China’s 4680 Battery Industry 485
18.4.8. Demand Forecast for EV 46xx Batteries 487
19. Forecast of Tesla 4680 Cell Production 489
19.1. Estimated Production at GIGA TEXAS 489
19.2. Tesla 4680 Battery Production Timeline and Key Milestones 490
19.3. Summary of Latest Tesla 4680 Battery Program 491
19.4. Cost Structure of Tesla 4680 Battery Cells 492
19.5. Efficiency Improvements and Cost Reduction Factors 492
19.6. Current Status of Tesla 4680 Cell Development 494
19.7. Recent Developments in Tesla 4680 and Supercharger Network 495
19.8. Summary of Tesla’s Battery Production and Lithium Refining Business 496
19.9. 4680 Cell Production Capacity vs. Cybertruck Output 498
19.10. Annual 4680 CAPA vs. Daily Production Output 499
19.11. 4680 CAPA vs. Production Time Trends 499
19.12. Major Assembly Processes at Tesla Giga Factory P/P Line 501