Available at: https://digitalcommons.calpoly.edu/theses/3104
Date of Award
6-2025
Degree Name
MS in Mechanical Engineering
Department/Program
Mechanical Engineering
College
College of Engineering
Advisor
Hyeonik Song
Advisor Department
Mechanical Engineering
Advisor College
College of Engineering
Abstract
Batteries with higher specific energy and power are essential for extending the range and performance of electric vertical takeoff and landing aircraft (eVTOLs). Anode-free lithium-metal pouch cells offer strong potential at the cell-level but require high compressive pressures to enhance cycle life and discharge performance. These pressures necessitate heavier structural components, reducing packaging efficiency at the module level.
To evaluate this tradeoff, a full-factorial enumeration model was developed to explore viable module designs within a constrained packaging volume. The model scales subsystem masses, enforces design rules and material limits, and accounts for large (~20%) cell thickness changes during cycling.
Results show that modules exceeding 300 Wh/kg and 1.5 kW/kg are achievable with commercially available lithium-metal cells. The study also recommends cell shape optimizations to further improve packaging efficiency. Despite simplifying assumptions, the model provides a practical tool for rapidly identifying optimal packaging strategies and supports the feasibility of these batteries for eVTOL applications.
Included in
Applied Mechanics Commons, Computer-Aided Engineering and Design Commons, Propulsion and Power Commons, Structural Materials Commons, Structures and Materials Commons, Systems Science Commons