1. Higher Energy Density Through Space Optimization By eliminating the curved "C-angles" inherent to wound cells, stacking technology maximizes space utilization within the battery cell. This results in a 5–6% increase in energy density compared to winding, as the layered design fully occupies corners and minimizes voids. For instance, prismatic and pouch cells utilizing stacked layers achieve up to 750 Wh/L, making them ideal for EVs requiring extended range without compromising pack size .

2. Enhanced Structural Stability The uniform stress distribution in stacked cells prevents localized deformation during charge-discharge cycles. Wound cells, by contrast, often suffer from uneven internal pressures at bends, leading to wave-like distortions and accelerated degradation. Stacked configurations maintain flat interfaces, reducing risks of delamination, electrolyte dry-out, and capacity fade—critical for batteries in heavy-duty industrial equipment or aerospace applications .

3. Improved Safety and Cycle Life Sharp bends in wound cells create weak points prone to coating cracks, burrs, and lithium dendrite formation. Stacking technology eliminates these vulnerabilities by ensuring even tension across all layers. Additionally, the parallel connection of multiple tabs in stacked cells reduces internal resistance by 30–40%, minimizing heat generation during fast charging. This translates to longer cycle life—up to 1,500 cycles at 80% capacity retention—and reduced thermal runaway risks .