Comparing the Bolt and Model 3 battery packs

GM Chevrolet Bolt EV Battery

There are two long-range, mid-priced EVs in town, and a (hopefully) friendly rivalry is developing between them. So, how do the two battery packs compare? A recent article in InsideEVs discusses the surprisingly large differences between the Chevy Bolt and Tesla Model 3 packs.

In a pair of lengthy videos from WeberAuto, Professor John Kelly disassembles a Bolt battery pack, and puts it back together again, revealing its inner workings in great depth.

No similarly detailed teardown videos for Model 3 have yet appeared on our screens, but InsideEVs’ George Bower offers some meaty technical details about Tesla’s new pack, which differs in many ways from GM’s product.

Bower finds that the Bolt pack is simpler to assemble, but the Tesla pack has it beat in terms of energy density. The rival packs employ very different cooling systems. Tesla’s features a ribbon-shaped cooling tube that snakes between the cells. This technique is also used in Model S, but in the Model 3, the individual cells are attached to the cooling ribbon, apparently with glue. The Bolt pack is much simpler – the individual prismatic cells simply sit on a cooling plate, separated from it by a thermal mat.

Another large difference between the Tesla and GM packs is their specific energy, at least at the module level – some painstaking calculations based on the weight of each module indicate that the Model 3 modules pack considerably more energy per kg. However, Bower points out that “Tesla’s battery chemistry is much more flammable than GM’s and it requires more armor to deflect foreign objects.” Therefore, Tesla’s case is likely heavier, which would negate part of the advantage in energy density.


Source: WeberAutoInsideEVs

  • Glenn_Blech

    I wouldn’t call the 3 “mid-priced” at an average of nearly 60 grand out the door.

  • Chris Jones

    And until the Model 3 battery is torn down and inspected as closely as GMs battery, I wouldn’t be declaring any winners…

  • dogphlap dogphlap

    Thank you very much for the two videos by Professor Kelly, they are by far the best disassembly videos I’ve ever seen. I’ll probably never get to see a Bolt since they are not available in RHD countries but if I was a US GM mechanic I’d be studying those videos carefully (plus any GM training materials I could get access to). I hope the Professor makes similar videos for the Tesla Model S and Model 3 some time. Everything shown in the two videos confirms the impression I already had that LG have done a very good job on the Bolt. Shame the steering rack had an fluid leak (and not a small one either), something for GM to follow up on I guess.