With increasing demands for higher ranges, lower costs, and higher charging performance in electric vehicles (EVs), innovative approaches for the structural integration of batteries are being implemented. This study investigates the response of 4680 cylindrical batteries, featuring nickel manganese cobalt oxide (NMC811) as the cathode active material, to quasi-static force application. The focus is on the implications for structural integration into next-generation EV battery systems. By subjecting the batteries to controlled quasi-static forces, the mechanical robustness and safety characteristics within these integrated systems are assessed. The methodology involves comprehensive testing protocols, including mechanical characterization, capacity analyses before and after deformation, thermal analysis, and the use of design of experiments (DOE) to systematically explore the influence of various mechanical failure scenarios on the cell’s behavior. Additionally, post-mortem analysis was conducted to check the cells for dissolved active material and assess any structural changes to the electrode composition. The findings from this study provide valuable insights for the development of new cell-to-chassis and cell-to-pack approaches to optimize the mechanical integration efficiency and thereby improving the energy density of next-generation EV battery system designs.

Electric vehicles offer a sustainable alternative to combustion engines but still face range and safety limitations. Integrating battery cells as structural elements (Cell-to-X, CTX) is a promising route to address both, but requires cells that reliably withstand everyday mechanical loads. This study presents a non-destructive mechanical characterization of commercial 4680-format cylindrical lithium-ion cells (Supplier 1), combining quasi-static compression tests (hemispherical and cylindrical indenters) across state of charge (SOC) and indentation depth, cyclic aging over up to 150 cycles, and post-mortem computed tomography (CT) analysis. Deformation remained predominantly reversible up to indentation depths of 0.5 mm for the hemispherical and 1.8 mm for the cylindrical indenter, and peak forces of up to 9.16 kN were sustained without functional or electrical failure, although localized plastic casing deformation was observed in individual cells at the highest tested depths. For the cylindrical indenter, peak force increased consistently with SOC and indentation depth, consistent with prior literature, while temperature and voltage remained stable throughout loading, with no immediate evidence of an internal short circuit. For the cells with a sufficiently complete cycling record, capacity loss over the valid cycles amounted to 1.8–2.9% per 100 cycles for the mechanically loaded cells, compared with 2.0% for an unstressed reference cell. Post-mortem CT imaging confirmed deformation remained confined to the outer casing and outermost jelly-roll layers without affecting internal structure or performance. These results provide preliminary evidence that the tested cells can tolerate structurally relevant mechanical loads without loss of function, supporting further development of CTX architectures.