The effect of pack design and cell chemistry selection on cradle-to-gate environmental impacts of battery manufacturing based on primary inventory data

Electrification offers the clearest pathway for emission reduction in the transport sector, causing rapidly growing demand for lithium-ion batteries. Developing battery packs that improve performance while reducing environmental impacts presents a key challenge. This study investigates how battery pack design and cell chemistry selection affect pack specific energy and, in consequence, cradle-to-gate environmental impacts. Primary teardown-based life cycle inventory data are provided for eight electric vehicle battery packs utilising NMC622, NMC811, NCA and LFP cell chemistries, covering around 50 materials and material groups. Cradle-to-gate environmental impacts are analysed with focus on climate change, highlighting the links between pack design and cell chemistry. Cell-to-pack ratios ranged from 56% to 82%, with baseline cradle-to-gate climate change impacts for the rest-of-pack ranging from 21 to 44 kg CO 2 -eq/kWh, contributing 19–33% of total pack impact. These findings underscore the importance of pack-level considerations in establishing energy dense and environmentally sustainable batteries for electric vehicles.