Cell-to-Pack (CTP)

Cell-to-pack is a battery design approach that installs cells directly in the pack without intermediate module housings, increasing the share of pack volume and mass occupied by cells and reducing part count.

In conventional designs, cells are first built into modules, each with its own frame, connections and sensing, which are then assembled into a pack. Cell-to-pack designs remove most module-level structure and place large groups of cells directly into the pack housing, using the cells, adhesives and the housing itself to provide stiffness. Widely known examples include CATL's CTP packs and BYD's Blade battery, whose long LFP cells span the pack. Cell-to-body or cell-to-chassis concepts go further by making the pack part of the vehicle structure.

CTP improves volumetric efficiency and can lower cost and simplify assembly, which has helped lithium iron phosphate cells reach practical vehicle ranges. It is increasingly common in new EV platforms.

Removing modules makes repair harder, because individual cells or groups are less accessible, and it places more emphasis on consistent cell quality, adhesive bonding and thermal propagation protection at pack level. Manufacturing relies on handling large-format cells, precise adhesive dispensing and automated inspection. Pack safety requirements remain governed by applicable regulations and standards.

Key points

Places cells directly in the pack without module housings
Improves volume utilisation and reduces parts
CATL CTP packs and BYD's Blade battery are widely known examples
Repair is harder and cell consistency becomes more critical

Where AiVibe comes in

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Cell-to-Pack (CTP)

Key points

Where AiVibe comes in

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