Which EV Battery Cell Type is Best? Prismatic, Cylindrical, or Pouch?

A friend of mine is planning to buy his first electric car. During our chat, he asked me if his EV should have prismatic cells or LFP batteries. That’s when I realised how confusing EV battery terms can be, especially in India. Most people use cell types and battery chemistries interchangeably, but they’re not the same.

This blog is a simple guide to help you understand the three main types of battery cells used in electric vehicles — Prismatic, Blade, Cylindrical, and Pouch. I’ll also share which ones are being used in EVs in India and what might be best for you.

What is the difference between cell type and battery chemistry?

Think of battery cells as the shape and structure (like the container), and chemistry as the material inside (like the ingredients). So, you can have LFP chemistry inside a prismatic cell or a pouch cell. They’re two separate aspects of a battery.

So when you hear someone say their EV has LFP batteries, that tells you the chemistry, but not the shape or structure of the battery cell.

What are Prismatic Cells and where are they used?

Prismatic cells are rectangular and often look like mini power banks. They’re designed to stack neatly, which makes them ideal for space optimisation inside battery packs.

Many Indian EVs, especially from Tata Motors and Mahindra, use prismatic cells — often with LFP chemistry.

Pros:

• Better packaging efficiency, especially in compact cars
• Flat surfaces make cooling easier
• Less chance of mechanical damage

Cons:

• Can be heavier due to the metal casing
• More expensive to manufacture than cylindrical cells

Example: The Tata Nexon EV and Mahindra XUV400 use prismatic cells with LFP chemistry. That’s one reason they’re considered safer and more stable in Indian conditions.

What are Blade Cells and are they used in India?

Blade cells are a special type of prismatic cell, but longer and thinner — almost like a ruler. The idea behind them is simple: stretch out the cell to make it easier to cool and safer to use. They’re designed by BYD and have gained attention for their performance in safety tests, including nail penetration and fire resistance.

In India, blade cells are already in use. The MG Windsor EV Pro (after BYD became a battery partner) and the BYD Atto 3 both use Blade batteries. These cars don’t just claim safety — they’ve passed global crash and fire safety tests with ease.

Why do Blade cells matter?

They help fix one of the few issues prismatic cells face — overheating. Since they’re thinner and more spread out, they cool faster and are less likely to catch fire even in extreme conditions. That makes them ideal for Indian summers and traffic-heavy city driving.

Pros:

• Better thermal management
• Space-saving design
• High safety under stress

Cons:

• Currently limited to select EVs
• Slightly more expensive to produce

So if your EV comes with Blade cells, that’s actually a good thing. You’re getting a version of prismatic cells that’s safer, cooler, and well-suited for Indian conditions.

What are Cylindrical Cells and where are they used?

Cylindrical cells are the oldest format used in lithium-ion batteries. They look like regular AA batteries, just bigger. These are often easier and cheaper to produce, and they have excellent thermal stability.

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In India, these cells are commonly found in electric two-wheelers and low-cost battery packs, especially from budget EV brands.

Pros:

• Cheaper to manufacture
• Proven and reliable design
• Good thermal management

Cons:

• Wastes space due to the cylindrical shape
• Not ideal for very compact battery designs

Example: Some electric scooters from Ampere and Hero Electric use cylindrical cells in their battery packs. These brands focus on affordability and scale, where cylindrical cells fit well.

What are Pouch Cells and where are they used?

Pouch cells look like silver plastic packets. They are the most flexible in shape and are often lighter. However, they’re also the most fragile of the three. They can swell over time and need more protective casing, which adds complexity.

They’re not very common in mass-market Indian EVs, mostly due to concerns around safety and durability in harsh Indian conditions.

Pros:

• Lightweight and compact
• Can be moulded into different shapes

Cons:

• More prone to swelling and damage
• Needs extra protection during packaging
• Higher risk in hot climates if not managed well

Example: Pouch cells are usually used in premium EVs or Hybrid EVs, where advanced battery management systems (BMS) are in place.

Prismatic vs. Cylindrical vs. Pouch Cells

If you are buying an electric car in India, chances are it’ll come with prismatic cells and LFP chemistry, which is a safe and stable combination. For scooters, cylindrical cells offer a good balance between cost and performance.

What about solid-state batteries?

You may have heard of solid-state batteries. These are not a new cell shape but a new battery technology, still in R&D stages. They promise more energy density and better safety but are not commercially available yet in India.

Interested in learning more about EV batteries? Check out our blog on LFP vs. Lithium-ion vs. Sodium-ion Batteries: Which EV Battery Is Best Explained.

Final thoughts

As EV adoption grows in India, the conversation around batteries will get more detailed. For now, most buyers don’t need to overthink it. But if you’re curious, knowing the difference between cell type and chemistry can help you make smarter choices.

So next time someone tells you their EV has “LFP batteries,” you can ask — “Cool, but are those prismatic or pouch cells?”