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

Elon Musk
Tesla vandal who lit Las Vegas repair center on fire arrested

A vandal in Las Vegas who lit a Tesla repair center on fire has been arrested, bringing a name and face to the crime that engulfed vehicles and a structure in flames.
Officers in Las Vegas arrested Paul Kim, a 36-year-old, on Wednesday. He faces charges of arson and possessing an explosive device.
The Tesla repair center at 6260 West Badura Avenue was set aflame on March 18 at around 2:45 a.m. In total, five vehicles were set on fire, as well as the building itself. It was one of the more notable instances of vandalism against Tesla in recent months, but police now have their culprit.
Las Vegas Metro Police Department Sheriff Dori Koren described the weapons Kim used to execute the attack:
“He used what appeared to be multiple Molotov cocktails and firearms to conduct his attack.”
As the instances of attacks on Tesla continue to be publicized, we are now seeing considerable pushback from owners, the company, and even the United States government regarding what it calls “domestic terrorism.”
Owners are now filing lawsuits against those who vandalize their vehicles, as the first civil suit against a vandal was filed in Texas yesterday.
Great
— Elon Musk (@elonmusk) March 27, 2025
Tesla has not made any moves itself against the vandals, but we expect the company to potentially enter some litigation against groups or politicians that incite violence against its property and the owners of its vehicles.
Additionally, the U.S. government has utilized the FBI to probe incidents against Tesla as a part of them being constituted as instances of domestic terrorism. Earlier this month, the Bureau established a specific task force to handle Tesla-related attacks.
“The FBI has been investigating the increase in violent activity toward Tesla, and over the last few days, we have taken additional steps to crack down and coordinate our response,” FBI head Kash Patel said on X. “This is domestic terrorism. Those responsible will be pursued, caught, and brought to justice.”
Elon Musk
Elon Musk clarifies Trump tariff effect on Tesla: “The cost impact is not trivial”
The U.S. President has stated that Elon Musk stayed silent and provided no input in the administration’s tariffs.

U.S. President Donald Trump’s plan to implement a 25% tariff on non-U.S.-made vehicles starting next week would affect American electric car maker Tesla.
This was confirmed by CEO Elon Musk in a recent post on social media platform X.
Musk and Trump
While Elon Musk works closely with the Trump administration due to his role in the Department of Government Efficiency (DOGE), the U.S. president has emphasized that the Tesla CEO never asks for favors. This was highlighted in his recent comments, when he stated that Elon Musk stayed silent and provided no input in the administration’s 25% auto tariffs.
When asked by reporters if the new tariffs would be good for Tesla, Trump noted that they may be “net neutral or they may be good.” The U.S. president also pointed to Tesla’s automotive plants in Fremont, California and Austin, Texas, which produce vehicles that are sold in the country. “Anybody that has plants in the United States — it’s going to be good for them,” Trump noted.
Tesla Affected
In a post on X, Elon Musk clarified that the Trump administration’s tariffs would affect the prices of vehicle parts that are sourced from other countries. This was a concern that Tesla previously outlined in a letter to the U.S. Trade Representative, which noted that even with “aggressive localization” of its supply chain, “certain parts and components are difficult or impossible to source within the United States.”
As per Musk in his recent post on X, the cost impact of the Trump administration’s tariffs is no joke. “To be clear, this will affect the price of parts in Tesla cars that come from other countries. The cost impact is not trivial,” Musk wrote in his post.
Potential Effects
Reactions to Musk’s comments from users of the social media platform were varied, with some speculating that the Trump auto tariffs could result in Teslas becoming more expensive in the United States. Despite this, the potential increases in Tesla’s vehicle prices might not be as notable as other cars, particularly those that are produced outside the country.
News
Hyundai’s $7.6B Georgia plant dodges Trump’s 25% Tariffs

Hyundai’s $7.6 billion Georgia plant dodged U.S. President Donald Trump’s recently announced tariffs on imported vehicles and auto parts.
The South Korean automaker’s Hyundai Motor Group Metaplant America (HMGMA) in Georgia celebrated its opening recently by announcing plans to expand the factory. Hyundai aims to boost production by two-thirds, increasing HMGMA’s capacity from 300,000 to 500,000 vehicles annually.
“This plant couldn’t come at a better time than now. Because definitely all the cars that we would produce here are going to be exempted from any tariffs,” said Hyundai Motor Company CEO Jose Munoz.
President Donald Trump recently announced 25% tariffs on auto imports at the White House. President Trump praised the HMGMA plan in Georgia, commenting it was a “clear demonstration that tariffs very strongly work.”
According to the Associated Press, the Georgia expansion ties into $21 billion in U.S. investments. It includes a $5.8 billion steel mill in Louisiana, which will supply parts for Georgia and Alabama plants.
Hyundai aims to employ 8,500 workers at the Bryan County site. Battery partners are estimated to add 3,500 more jobs. The car company does not have worker estimates for HMGMA’s expansion plans.
Hyundai Motor Group Executive Chairman Euisun Chung said the legacy automaker came to Georgia “to stay, to invest and to grow.”
“Standing here today, I can say I have never been more confident about building the future of mobility with America, in America,” Chung said.
Hyundai started EV production in Georgia six months ago. As of this writing, over 1,200 workers run the massive plant. Hyundai’s Georgia factory builds two electric SUVs now. The IONIQ 5 is already in production. Hyundai will start producing the IONIQ 9 this spring. Hyundai plans to produce hybrids, too. Munoz predicted hybrids would eventually make up one-third of production.
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