MonoLith Battery Systems

35 kWh Lithium-Ion Battery Packs

162 validated MonoLith configurations from 30 to 40 kWh, 65 to 853 V nominal, up to 477 kW peak.

Configurations
162
Voltage Range
65–853 V
Peak Power
97–477 kW
Mass Range
221–358 kg
Gravimetric Density
107–142 Wh/kg

Configuration Explorer

Each point is one validated MonoLith configuration. Toggle between rated and peak power. Click a point to open it in PackForge.

8312516821025325242459676893Nominal Voltage (V)Rated Discharge Power (kW)
AluminumCopper

162 of 162 configurations shown. Click a point to open it in PackForge.

What Limits Each Pack

How many configurations are limited by each factor during full-capacity and peak discharge.

Full-Capacity Discharge Limited By

Collector110Cell33Busbar19
Collector(110 configurations)

Collector thermal bound, not energy bound. A copper collector raises the sustained current limit.

Cell(33 configurations)

Energy bound by cell capacity at the tested discharge rate.

Busbar(19 configurations)

Peak Discharge Limited By

Cell66Busbar50Collector46
Cell(66 configurations)

Energy bound by cell capacity at the tested discharge rate.

Busbar(50 configurations)
Collector(46 configurations)

Collector thermal bound, not energy bound. A copper collector raises the sustained current limit.

Fit Check

Enter your maximum envelope dimensions to see which configurations fit.

Fitting Configurations
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Lightest That Fits
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Highest Power That Fits
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Band dimension range: 1,168–1,368 mm L × 803–900 mm W × 170–170 mm H

Open in PackForge with envelope

Load and Runtime Estimator

Pick a configuration and enter your average load to estimate runtime and cell thermal behavior.

Select a configuration and enter an average load to see estimated runtime.

Cell and Collector Test Data

These charts come from P50B cell tests, collector plate tests, and a drive-cycle simulation of a reference pack. They show the cell and interconnect behavior shared by every configuration on this page; they are not 25 kWh pack test results.

Inside the Pack

The Cell at the Core

Every MonoLith pack is built around a single cell chemistry we've validated across hundreds of test hours. The pack engineering — collector plates, thermal architecture, wire bonding — is where EVolve adds value. The cell is the foundation we chose carefully, not the product we sell.

Molicel INR-21700-P50B cylindrical cell — the cell used inside MonoLith packs

The cell inside every MonoLith pack. A 21700-format power cell chosen for its balance of energy density, discharge capability, and cycle life.

Format
21700 cylindrical
3.6 V nominal
Capacity
5.0 Ah
18 Wh per cell
Energy density
265 Wh/kg
714 Wh/l
Max discharge
60 A
cut off at 80 °C
DC impedance
12.8 mΩ
typical, new cell
Fast charge
5C
25 A charge rate
NoteSpecifications are manufacturer-published reference data with no performance guarantee. Pack-level behaviour differs from single-cell data — see the thermal charts below.

Why This Cell

Silicon-carbon composite anode

The anode formulation is what doubled cycle life from 700 to 1,400 cycles at the cell level. Silicon-carbon composites accommodate more lithium per unit volume than conventional graphite, but managing the volume expansion during cycling is the engineering challenge — and the reason the cycle life gain is real.

High-nickel layered oxide cathode

Higher nickel content pushes energy density and power delivery. The trade-off is thermal sensitivity at high states of charge, which is exactly what the thermal charts on this page quantify.

Low-temperature electrolyte formulation

The electrolyte is formulated to maintain ionic conductivity at low ambient temperatures, extending the usable charge window below 0 °C.

Cycle Life

1,400 cycles

At 23 °C, cell level, with +1C charge and −100 W discharge. A packed module runs hotter, so real-world cycle life is lower. We model pack-level degradation against your duty cycle and cooling design — the number above is a best-case anchor, not a field prediction.

Peak Power (10 s)

397 W
25 °C
288 W
50% SOC
238 W
−10 °C

Per cell, 10-second pulse. Pack power scales with cell count. These are manufacturer reference figures — actual sustained output depends on thermal management, which is what the next section explores.

This cell is used in hyper EVs, racing programs, eVTOL, and heavy-lift drone applications. Molicel cells power the McMurtry Spéirling, which holds the Goodwood Festival of Speed hill climb record — a legitimate halo for the cell we build around, and a data point on what the chemistry is capable of in the right hands.

So how does this cell actually behave under load? That's the next section.
Thermal Performance

Why a Single "Continuous Power" Rating Is the Wrong Question

A vehicle doesn't draw constant peak power. Load profile and thermal management determine what a pack actually delivers. These three stories show why — using measured test data and engineering models from our Molicel INR-21700-P50B cell testing.

01

Discharge Rate Changes What You Get

At low rates the cell delivers full capacity. At high rates it heats up, hits its 80°C limit partway through, and terminates early with less than half its capacity delivered. There is no single "continuous" number — there's a curve.

Molicel INR-21700-P50B, single cell, free convection. 12 discharge rates from 1C to 12C.
0 of 12 rates shown
20°C40°C60°C80°C0m10m20m30m40m50m60m80°C cell limitTime (minutes)Cell Temperature (°C)
Single cell in free convection. A populated pack runs hotter and will cut out earlier at high rates — these figures are a best case.
02

Copper Collector Plates: When They Matter

At low current, aluminium and copper both run cool — copper is overkill. As current rises, aluminium heat-soaks quickly while copper stays flat. At high current aluminium exceeds its limit and copper doesn't.

Al thermal time constant: 6.0 min. Copper: 11.2 min. That difference in shape is the story.
Step 1 / 6
25°C50°C100°C150°C200°C130°C plate limit0m10m20m30m200ATime (minutes)Plate Temperature (°C)
AluminiumCopperSolid = measured (400A only)Dashed = modelled
Aluminium sustains
540 A
Copper sustains
744 A (+38%)
Note:400 A rows are measured test data; all other currents are modelled from that anchor. Axis capped at 700 A — beyond that the model is well past anything measured.
03

Real Duty Cycles vs. Constant-Load Rating

A simulated vehicle drive cycle (hard acceleration, cruising, regen, stops) against the same pack held at constant peak power. The drive cycle stabilises comfortably; the constant load exceeds the cell limit in minutes. Same pack, same cooling.

576 cells, 10.4 kWh, 125 kW peak
11% of cycle above 70 kW, averages 25 kW
25°C50°C75°C100°C0m10m20m30m40m80°C cell limit050100130 kWTime (minutes)Cell Temperature (°C)
Power demand (kW, right axis)Drive cycle, liquid
Drive cycle, liquid-cooled
53°C
Stable indefinitely
Simulated drive cycle — cooling performance not yet validated by test. All physical testing to date is still air. Not a WLTP or FTP-75 standard cycle.

The right question isn't "what's the continuous rating?"

It's "what does my application actually draw, and how does the pack handle that?"

Request a Thermal Assessment
Physical Test Data

Liquid Cooling, Proven on Hardware

Four modules in one pack. Same cells, same current, same instant. Two had the conductive pad removed — a 2 mm air gap to the cold plate. Two were actively liquid-cooled. The temperature difference between them is the cooling system's effect and nothing else.

180 A (7.5 A/cell) — 28.9 min under load
Air gap (uncooled)Liquid cooled
20°C30°C40°C50°C60°C0m10m20m30m40m50m60m70m80m53°C test limit24°C ambientTime (minutes)Cell Temperature (°C)
Dashed line marks load removal. After load-off, cooled modules shed heat far faster than uncooled — a second, independent demonstration of the same effect.
11 K
Cooling Benefit
47°C uncooled → 36°C cooled
No
Uncooled Hit Test Limit
Ended on minimum cell voltage (2.5 V)
17 K
Cooled Headroom to Limit
Below 53°C test limit
1.92×
Conductance Ratio
Cooled vs uncooled (CH1)
TestPack CurrentLoad DurationUncooled PeakCooled PeakBenefitUncooled Hit Limit
CH1180 A28.9 min47°C36°C11 KNo
CH2360 A10.1 min52°C43°C9 KYes

The 360 A run is the one that matters

The uncooled modules reached the 53°C test limit and the run ended. The cooled modules sat at 43°C with 10 K of headroom. Cooling didn't just lower a number — it was the difference between finishing the run and stopping.

What this test is — and isn't

A physical test on a real four-module pack. Peak temperatures are measured from the test report; curve shape between start and peak is reconstructed from published figures. The 53°C line is a test limit, not a cell limit — the cells tolerate considerably more. This shows cooling works and by how much at these currents; it does not establish maximum heat rejection.

Test used a four-module, 24-cell-per-module pack. Peak temperatures are measured; curve shape is reconstructed from published figures. The 53°C line is a test limit, not a cell limit.

Full Configuration Table

162 configurations. Click any part number to open it in PackForge.

Part Number V ↑kWh Ah Rated kW Peak kW Hold (min) Mass (kg) Wh/kg
1SPC-018S4P-031.1A564.831.148097.297.219287108.2
1SPA-018S4P-031.1A564.831.148097.297.219225138.1
1SPA-019S4P-032.8A568.432.8480102.6102.619234140.2
1SPC-019S4P-032.8A568.432.8480102.6102.619299109.7
1SPC-020S4P-034.6A572.034.6480108.0108.019311111.0
1SPA-020S4P-034.6A572.034.6480108.0108.019243142.2
1SPC-021S4P-036.3A675.636.3480113.4113.419334108.8
1SPA-021S4P-036.3A675.636.3480113.4113.419261138.9
1SPC-022S4P-038.0A679.238.0480118.8118.819346110.0
1SPA-022S4P-038.0A679.238.0480118.8118.819270140.7
1SPC-023S4P-039.7A682.839.7480124.2124.219358111.1
1SPA-023S4P-039.7A682.839.7480124.2124.219279142.5
1SPA-024S3P-031.1A586.431.1360111.5129.614225138.1
1SPC-024S3P-031.1A586.431.1360129.6129.614287108.2
1SPA-025S3P-032.4A590.032.4360116.1135.014232139.7
1SPC-025S3P-032.4A590.032.4360135.0135.014296109.3
1SPA-026S3P-033.7A593.633.7360120.7140.414239141.2
1SPC-026S3P-033.7A593.633.7360140.4140.414305110.3
1SPA-027S3P-035.0A697.235.0360125.4145.814255137.4
1SPC-027S3P-035.0A697.235.0360145.8145.814325107.8
1SPA-028S3P-036.3A6100.836.3360130.0151.214261138.9
1SPC-028S3P-036.3A6100.836.3360151.2151.214334108.8
1SPA-029S3P-037.6A6104.437.6360134.7156.614268140.3
1SPC-029S3P-037.6A6104.437.6360156.6156.614343109.7
1SPA-030S3P-038.9A6108.038.9360139.3162.014275141.6

Page 1 of 7 — showing 25 of 162 configurations

Multi-pack configurations combine identical MonoLith packs; see PackForge for wiring and interconnect details.

Frequently Asked Questions

Configurations in this band span 64.8 V to 853.2 V nominal.

Mass ranges from 221 kg to 358 kg across the 162 configurations.

Cell models in this band: INR-21700-P50B (162 configs).

Cooling methods: Liquid cooled, -8 AN fittings (162 configs).

Yes. Use PackForge to filter by any voltage, energy, or power band, or submit an RFQ for a custom configuration.

Apply this to your program

EVolve Battery Systems designs and manufactures custom lithium-ion battery packs in Boulder, Colorado. Every MonoLith configuration on this page is built on the same engineering platform.