Battery Pack Sizing Calculator

Size an EV battery pack based on desired range, vehicle weight, and efficiency targets.

Input Parameters

Results

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Gross Battery Capacity
kWh
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Usable Battery Capacity
kWh
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Est. Pack Weight
lbs
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Total Vehicle Weight
lbs
Note: Modern EV cells achieve 250-300 Wh/kg. Pack-level density drops to ~160-190 Wh/kg due to cooling, BMS, enclosure, and wiring. Heavier batteries increase energy consumption, creating a compounding weight spiral.

Reference

Usable kWh = Target Range × Wh/mi / 1000 Gross kWh = Usable / 0.90 (10% buffer top/bottom) Pack Density ≈ Cell Density × 0.65 (packaging overhead) Pack Weight = Gross kWh × 1000 / Pack Density Total Vehicle Weight = Curb Weight + Pack Weight