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Tesla 4680 cells compared with BYD Blade and CATL Qilin structural batteries

Image used with permission for Teslarati. (Credit: Tom Cross)

Published

3 years ago

December 7, 2022

Simon Alvarez

The battle for the dominance of the electric vehicle sector would likely be determined by the market’s key battery makers. With this in mind, companies such as BYD, CATL, and Tesla — all of whom are exploring the structural battery form factor — have the chance to become the trailblazers of the next generation of electric car batteries.

During its Battery Day event, Tesla announced its 4680 cells, which are used alongside the company’s structural battery pack. BYD, on the other hand, has also released its Blade batteries, which also adopt a non-modular approach. CATL’s Qilin batteries are in the same segment, with its structural battery design.

Electric vehicle battery enthusiast Jordan Giesige of YouTube’s The Limiting Factor channel recently conducted a comparison of the advantages and disadvantages of Tesla, BYD, and CATL’s next-generation structural packs. Each battery pack was evaluated according to several factors, such as design, rigidity, packing and energy density, and safety, before being ranked. It should be noted that the figures used in the comparisons are drawn from estimates and materials released by Tesla, BYD, and CATL themselves, not current real-world observations.

As noted by Giesige, Tesla’s 4680 structural battery packs utilize hundreds of cylindrical cells with a cooling ribbon in between every other row of cells. A lid is then placed on top and polyurethane foam is injected into the pack. This polyurethane hardens, and the combination of the foam and the battery cells forms a rigid, honeycomb-type structure.

CATL Qilin batteries, which could be fitted with both nickel and iron-based cells, integrate thermal pads, the liquid cooling plate, and the cross bracing to create what could be described as structural cooling. The structural cooling is placed between each row of prismatic battery cells, and the cells themselves are placed into the pack directly without any modules. BYD Blade batteries use iron-based prismatic cells, though these cells are longer and thinner than those used by CATL. The cells are then stretched across the BYD Blade battery pack, allowing the cells themselves to replace conventional steel beams.

In the rankings of the next-generation batteries, the YouTube host noted that Tesla’s 4680 structural battery pack would likely be the most rigid among its peers. Tesla’s 4680 pack loses out in terms of packing density, however, as BYD and CATL’s use of prismatic cells maximizes volumetric energy density. With this in mind, and considering that CATL’s Qilin batteries can be fitted with high-energy density nickel-based cells, a nickel-based Qilin battery would likely be more energy dense than a nickel-based Tesla 4680 pack or a BYD Blade structural battery, which uses less energy dense iron-based cells.

As for cooling, Giesige noted that the BYD Blade batteries’ plate cooling would likely fall short of the Tesla 4680 pack and CATL Qilin battery’s cooling systems. In its marketing materials, CATL highlighted that cooling the sides of the Qilin battery increases the pack’s cooling area four times. Tesla’s 4680 battery also uses better cooling than BYD’s Blade batteries with its side cooling system, though it would likely not be as good as the cooling of CATL’s Qilin structural packs.

While BYD’s Blade batteries lose out in cooling, they are also likely the safest among its peers. This is because the BYD Blade battery uses iron-based cells, which have a higher decomposition and lower heat release temperature than the nickel-based cells used in Tesla’s 4680 cells and CATL’s nickel-based Qilin batteries. An iron-based Qilin battery comes second to the BYD Blade, partly due to its use of shorter and thicker prismatic cells, which may trap more heat.

A Qilin pack with nickel-based cells was ranked last in terms of safety by the battery enthusiast, as Tesla’s 4680 pack with nickel-based cells features several safety systems, such as an overpressure mechanism on the bottom of the cells themselves. Since 4680 cells are also smaller than the prismatic cells used in the BYD Blade and CATL Qilin, they contain less energy. The 4680 cells themselves are enclosed in a thick shell as well, which are about 2-3 times thicker than a conventional battery.

Overall, Giesige noted that Tesla’s 4680 cells are likely the best all-rounder compared to its peers in the structural battery segment. The overall scores of the BYD Blade and CATL Qilin batteries bode well for Tesla’s future, however, as the companies could become suppliers of the EV maker in the future. CATL is already supplying Tesla with LFP batteries today, and BYD is heavily rumored to be a Tesla supplier as well. In a way, the analysis of the next-generation structural EV batteries shows that Tesla is not alone in pushing the battery industry forward.

Watch The Limiting Factor‘s full analysis in the video below.

Don’t hesitate to contact us with news tips. Just send a message to simon@teslarati.com to give us a heads up.

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Tesla Cybercab sightings on public roads are becoming more frequent

After it was unveiled a year ago by Tesla, the company has made some pretty drastic jumps in progress in terms of the Cybercab, but a recent development has truly pushed fans of the company to think it is probably going to be available soon.

Published

1 hour ago

November 6, 2025

Joey Klender

Credit: Petersen Museum

Tesla Cybercab sightings on public roads are becoming much more frequent, and they all are pointing to one thing: imminent production.

The Tesla Cybercab is the company’s vehicle developed for fully autonomous travel, as it will be manufactured without a steering wheel or pedals, according to CEO Elon Musk.

Tesla Robotaxi Cybercab: Seats, price, special features, release date, and more

Last week, we reported on the first Cybercab sighting when the vehicle was finally being tested on public roads. The spotting was not a one-time deal, as we are now seeing many more sightings on public roads:

Saw it the other day pic.twitter.com/uv0geR6GIh

— Shareef Mahmoud (@saltyyshareef) November 6, 2025

The first spotting was in Palo Alto, just a few blocks from Tesla’s Engineering Headquarters in Los Altos. This second sighting appears to be relatively close to that first spotting, and it seems unlikely Tesla would be putting it on roads much further than that.

The public on-road testing of the Cybercab marks a major milestone in the entire project for Tesla. These early sightings and testing phases are usually followed by a lot of speculation about when the vehicle could end up in the hands of customers.

However, Tesla has already put a definitive date on when Cybercab production will begin, as Elon Musk said during the Q3 Earnings Call that it would roll off production lines in Q2 of next year.

But the speculation regarding the Cybercab is slightly different than other vehicles because Tesla has been developing it for fully autonomous travel; it’s not meant to be driven by humans but instead by software and the company’s Full Self-Driving suite.

Despite the vehicle being spotted with a steering wheel and pedals in the recent sightings, Musk has maintained that the Cybercab will not be developed with typical controls for a human. He recently confirmed this, and it does not seem the company is willing to veer too much from its plans for an autonomous car.

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Tesla Model Y Performance is rapidly moving toward customer deliveries

New drone images from noted drone operator and Gigafactory Texas observer Joe Tegtmeyer show Tesla is moving forward quickly in terms of its progress in producing the new Model Y Performance.

Published

2 hours ago

November 6, 2025

Joey Klender

Credit: Tesla

Tesla has rapidly progressed in the production of its most anticipated Model Y trim level: the Model Y Performance.

New drone images from noted drone operator and Gigafactory Texas observer Joe Tegtmeyer show Tesla is moving forward quickly in terms of its progress in producing the new Model Y Performance.

The vehicle is being spotted more frequently at the factory located just outside of Austin, with what appears to be the first units rolling out to outbound lots:

In case you missed the news, Giga Texas has begun Model Y Performance production. Now all variants of the Model Y (except the China-only YL) are built in Texas. pic.twitter.com/AOOB9jtLwN

— Joe Tegtmeyer 🚀 🤠🛸😎 (@JoeTegtmeyer) November 6, 2025

In the United States, Tesla unveiled the Model Y Performance on September 30, the newest iteration of the fastest trim level of the best-selling car in the world for the past two years. It was launched on the very last day of the $7,500 electric vehicle tax credit in the United States.

It featured a handful of performance improvements, including a 0-60 MPH acceleration rate of 3.3 seconds, a trim from the 3.5 seconds the 2025 version offered.

Additionally, the range has gone from 277 miles to 308 miles, a notable improvement in terms of how far it can travel on a charge.

There are also a handful of hardware changes that Tesla made to improve its aerodynamic performance, which all likely can be attributed to the boost in speed and acceleration, as well as range.

The vehicle was initially launched in Europe, which was not surprising, especially as Tesla was testing the new Performance trim at the famed Nurburgring in Germany.

Deliveries are currently slated for late November, but some orders are getting projections of mid-December for their Model Y Performance, which would help Tesla bolster its end-of-year delivery figures and follow up on an extremely bullish finish to Q3, which was the company’s strongest performance in history.

Elon Musk

Twitter co-founder Jack Dorsey endorses Elon Musk Tesla pay package

Dorsey framed the pay package as an engineering and governance crossroads for Tesla.

Published

4 hours ago

November 6, 2025

Simon Alvarez

Twitter co-founder and Square CEO Jack Dorsey has publicly backed Elon Musk’s leadership ahead of Tesla’s pivotal shareholder vote, which is expected to be decided later today at the company’s 2025 annual meeting.

Dorsey framed the pay package as an engineering and governance crossroads for Tesla.

Dorsey’s public nod framed as an engineering defense of Musk

In a post on X, Dorsey weighed in on Tesla’s post about being in a “critical inflection point.” As per the Twitter-co-founder, the vote on Musk’s 2025 performance award is not about compensation. Instead, it’s about ensuring the path for the company’s engineering in the coming years.

“This is not about compensation. it’s about ensuring a principled (and exciting!) engineering approach to the company’s future,” Dorsey wrote on his post, later stating that users of Cash app with TSLA shares would be able to vote for the CEO’s proposed 2025 performance award.

Elon Musk appreciated Dorsey’s endorsement, responding to the Twitter co-founder’s post with a heart emoji. Musk has been pretty thankful for the support for is fellow tech executives, also thanking Michael Dell recently, who also advocated for its proposed 2025 performance award.

❤️— Elon Musk (@elonmusk) November 6, 2025

Musk’s support

While Elon Musk’s 2025 performance award has received opposition from proxy advisors such as Glass Lewis and ISS, it has received quite a lot of support from longtime bulls such as ARK Invest, and, more recently, Schwab Asset Management following calls from TSLA retail shareholders.

“Schwab Asset Management’s approach to voting on proxy matters is thorough and deliberate. We utilize a structured process that focuses on protecting and promoting shareholder value. We apply our own internal guidelines and do not rely on recommendations from Glass Lewis or ISS. In accordance with this process, Schwab Asset Management intends to vote in favor of the 2025 CEO performance award proposal. We firmly believe that supporting this proposal aligns both management and shareholder interests, ensuring the best outcome for all parties involved,” Charles Schwab told Teslarati.