Tesla’s Model 3 carries roughly 24 percent higher pack energy density as compared with a 2018 Nissan Leaf, according to data compiled by BloombergNEF research. That resulted in about 90 miles more range, though weight considerations and Nissan’s smaller battery size also factor in.
Tesla also uses a different battery chemistry — aluminum, in addition to the standard nickel and cobalt — than other major automakers. The battery researchers said that choice has led to maximum range because of a higher-capacity battery chemistry, though downsides included a higher fire risk and shorter cycle life, or life span over hundreds of charges.
Other automakers have opted for manganese instead of aluminum, with lower storage capacity, portending less range but potentially longer life cycles, those researchers said.
The tradeoff for Tesla: higher energy densities and higher-capacity materials tend to put out more heat, requiring more advanced cooling systems and temperature management systems to preserve the battery, the researchers and analysts said.
Will Chueh, a Stanford University’s Department of Materials Science and Engineering professor who focuses on lithium-ion batteries, said Tesla’s choice of battery material also represents another bet: more range means less charging, offsetting some concerns about cycle life. Consumers won’t have to charge their cars as much if they have 300 miles of available range, so Tesla can afford to use a battery with a shorter cycle life, in addition to taking proactive measures such as active cooling to preserve the life of the battery. “The larger the battery is the fewer times you have to cycle it," he added.