Battery Size Chart
Battery Size Chart: The Complete Guide to All Your Battery Dimensions
Finding the right battery is never just about voltage or capacity—it starts with the physical dimensions. If a battery is a millimeter too wide, a fraction too thick, or the wrong shape altogether, it simply will not fit, and no amount of technical specification can rescue a dimensional mismatch. This guide breaks down dimension conventions across the seven major battery categories—Cylindrical Batteries, Prismatic LiFePO4 Batteries, Polymer Lithium-ion Batteries, Coin Button Batteries, LiFePO4 Battery Packs & Modules, 9V Rechargeable Batteries, and Portable Energy Storage Power Stations—so you can skip the guesswork and pick the right power source the first time around.
If you are looking for a broader overview of the product families we carry, our product catalog organizes everything by chemistry, form factor, and application. For those who want to dig deeper into specific cell comparisons, we have a detailed article breaking down the differences between the two most popular cylindrical formats in our 18650 vs 21700: The Ultimate Comparison Guide—a recommended read if you are upgrading a flashlight, a power tool pack, or an EV module.
1. Cylindrical Batteries: The Industry Workhorse
Cylindrical lithium-ion batteries are ubiquitous. From laptop battery packs to Tesla’s vehicle floorpans, their standardized naming convention makes size identification refreshingly straightforward. The five-digit model number encodes the approximate physical dimensions: the first two digits denote the diameter in millimeters, the next two denote the length in millimeters, and the trailing zero signals the cylindrical form factor.
Here is the core dimensional reference for the most common cylindrical lithium-ion cells:
| Model | Diameter (mm) | Height (mm) | Typical Capacity (mAh) | Common Applications |
|---|---|---|---|---|
| 14500 | 14 | 50 | 600–1000 | Flashlights, small electronics (AA-sized Li-ion) |
| 16340 | 16 | 34 | 600–800 | Compact flashlights, laser pointers (CR123A equivalent) |
| 18350 | 18 | 35 | 700–1200 | Compact vape mods, small power tools |
| 18500 | 18 | 50 | 1000–2000 | Mid-size flashlights, solar garden lights |
| 18650 | 18 | 65 | 1500–3500 | Laptop packs, power tools, e-bikes, Tesla Model S/X (original) |
| 21700 | 21 | 70 | 4000–5600 | Tesla Model 3/Y, high-drain power tools, e-scooters |
| 26650 | 26 | 65 | 3000–5500 | High-capacity flashlights, off-grid storage modules |
| 26700 | 26 | 70 | 4000–6000 | Industrial equipment, large power banks |
| 32650 | 32 | 65 | 5000–7000 | Solar storage, UPS systems |
| 46800 (4680) | 46 | 80 | Up to 25,000 | Next-gen EVs (Tesla Cybertruck, Model Y structural pack) |
The jump from one format to the next involves more than just numbers. The 21700 cell, for instance, offers roughly 20% higher volumetric energy density compared to the 18650 when comparing the same cathode chemistry.The 4680 cell takes this scaling logic to its extreme: its volume is approximately 704% that of an 18650, with a corresponding leap in nominal energy per cell from around 10 Wh to as high as 98–118 Wh.
For a thorough side-by-side breakdown of how these two formats compare in real-world applications, our 18650 vs 21700 Ultimate Comparison Guide covers energy density, heat dissipation, and device compatibility in depth.
Beyond the headline dimensions, there are practical nuances to keep in mind. Protected cells—those with a built-in protection circuit board (PCB)—add roughly 2–3 mm to the length and a fraction of a millimeter to the diameter. A protected 18650 can measure closer to 68–70 mm long, which may prevent it from fitting into a spring-loaded flashlight or a tight charger bay designed for bare 65 mm cells. Similarly, button-top cells (with a protruding positive terminal) can be 1–3 mm longer than flat-top equivalents. Always check your device’s specification for the maximum allowable cell length.
Cylindrical cells also span multiple chemistries. Li-ion cells deliver a nominal 3.6–3.7V. LiFePO4 cylindrical cells—commonly in 18650, 26650, and 32650 formats—run at a nominal 3.2V. Standard consumer alkaline and NiMH sizes (AA: 14×50 mm, AAA: 10.5×44.5 mm, C: 26.2×50 mm, D: 33.2×61.5 mm) share similar or identical diameters to some lithium formats but operate at 1.5V and 1.2V respectively, and are generally not interchangeable without a device designed for both voltage ranges.
2. Prismatic LiFePO4 Batteries: Rectangular Power for Deep-Cycle Applications
Prismatic cells are the format of choice for applications that demand high capacity in a space-efficient rectangular package. Instead of a rigid steel can, they use a flat aluminum or steel enclosure that stacks internal electrode layers, maximizing volume utilization. In the LiFePO4 space, prismatic cells dominate solar energy storage, marine house banks, electric forklifts, and low-speed vehicles precisely because their geometry packs neatly into rack-mount frames and compartmentalized enclosures.
Prismatic LiFePO4 cells are identified by capacity and external dimensions expressed as Thickness × Width × Height (or Length × Width × Height, depending on manufacturer convention). There is no universal model-number-to-size formula as with cylindrical cells, which makes having a reference chart essential. Below is a representative survey of commercially available LiFePO4 prismatic cells across the capacity spectrum:
| Capacity (Ah) | Nominal Voltage | Approx. Dimensions (mm) | Approx. Weight (g) | Typical Cycle Life | Common Use |
|---|---|---|---|---|---|
| 22 | 3.22V | 148.7 × 17.7 × 131.8 | 628 ± 20 | 4,500 cycles | Small backup systems, portable electronics |
| 32 | 3.2V | 148.3 × 26.8 × 94.3 | 730 ± 50 | 3,500 cycles | Compact solar setups, mobility scooters |
| 50 | 3.2V | 148.3 × 26.7 × 129.8 | 1,035 ± 100 | 1,500–7,000 cycles (varies by sub-model) | Telecom backup, small UPS |
| 82 | 3.2V | 130.3 × 36.3 × 170.5 | 1,680 ± 50 | 4,000 cycles | Residential solar storage, electric three-wheelers |
| 90 | 3.2V | 130.3 × 36.3 × 200.5 | 1,994 ± 100 | 6,000 cycles | Home energy storage, AGV robots |
| 101–102 | 3.2V | 160.0 × 50.1 × 118.5 | 1,920 ± 100 | 2,000–5,000 cycles | Mid-size solar banks, marine |
| 230 | 3.2V | 54 × 174 × 207 | 4,200 | 4,000 cycles | Large off-grid storage, EV packs |
| 304 | 3.2V | 207.2(H) × 173.7(W) × 71.7(T) | 5,450 ± 164 | 4,000 cycles | Grid-scale energy storage, commercial solar |
The dimensional variation across capacities is driven by different internal electrode designs and manufacturers’ optimization for specific applications. High-cycle variants (like certain 50 Ah models rated for 7,000 cycles) tend to be slightly heavier per amp-hour because they use thicker electrodes that tolerate repeated expansion and contraction.
It is also worth noting that prismatic LiFePO4 cells are a core building block for assembled battery packs. We will discuss pre-built pack dimensions in Section 5, but when sourcing raw cells for a DIY build, always verify the terminal type (welded stud vs. bolt-on vs. laser-weldable tab) and the cell’s expected swelling allowance—prismatic cells can expand by 1–3 mm across the thickness over thousands of cycles, and enclosures must accommodate that growth.
3. Polymer Lithium-ion Batteries: Thin, Flexible, and Shape-Adaptable
Lithium polymer (Li-Po) batteries represent the ultimate in form-factor flexibility. Unlike cylindrical or prismatic cells encased in rigid metal shells, Li-Po cells use a soft aluminum-laminated pouch film, allowing thicknesses below 1 mm and enabling curved or irregular shapes that conform to the device housing itself.
The trade-off is mechanical robustness: pouch cells lack the structural rigidity of steel-cased cylindrical cells and must be protected from puncture, crushing, and excessive swelling. But for applications where every millimeter of device thickness counts—smartphones, tablets, Bluetooth earbuds, wearables, GPS trackers, and ultra-thin power banks—Li-Po is irreplaceable.
Li-Po cell dimensions are expressed as Thickness × Width × Length (in mm), and many manufacturers embed these numbers directly into the model code. For example, a cell labeled “503450” measures 5.0 mm thick × 34 mm wide × 50 mm long. Here is a representative sampling of standard Li-Po sizes across common capacity bands:
| Model Code | Dimensions (T×W×L, mm) | Nominal Voltage | Capacity (mAh) | Approx. Weight (g) | Typical Application |
|---|---|---|---|---|---|
| 402030 | 4.0 × 20 × 30 | 3.7V | 180 | ~5 | Wearables, fitness trackers |
| 403035 | 4.0 × 30 × 35 | 3.7V | 400 | ~10 | Bluetooth headsets, smart rings |
| 503450 | 5.0 × 34 × 50 | 3.7V | 850 | ~20 | MP3 players, small IoT devices |
| 604260 | 6.0 × 42 × 60 | 3.7V | 2,000 | ~45 | Tablets, GPS navigators |
| 803450 | 8.0 × 34 × 50 | 3.7V | 1,500 | ~35 | Portable media players, handheld consoles |
| 5564113 | 5.5 × 41 × 113 | 3.7V | 5,000 | ~110 | Large tablets, portable speakers |
| 9759156 | 10.5 × 61 × 160 | 3.7V | 10,000 | 207 | High-power drones, medical devices |
| 1055275 | 10.5 × 55 × 275 | 3.7V | 21,000 | 406 | E-bikes, robotic platforms |
The practical advantage of Li-Po cells extends beyond raw dimensions. Polymer cells are approximately 40% lighter than equivalent-capacity steel-cased lithium cells and 20% lighter than aluminum-cased lithium cells.This weight saving, combined with the ability to produce cells thinner than 1 mm, makes polymer cells the default choice for modern consumer electronics where industrial design dictates the battery shape rather than the other way around.
When selecting a Li-Po cell, pay close attention to tolerance specifications. Standard manufacturing tolerances are typically ±1 mm on length and width, and ±0.2–0.3 mm on thickness.A 0.5 mm thickness deviation may not sound like much, but in a smartphone with a designed battery cavity of 4.0 mm, a cell that arrives at an actual 4.5 mm can prevent the display from seating properly. Also, high-discharge Li-Po cells (10C or above) tend to be slightly thicker than low-drain equivalents of the same capacity, as they incorporate thicker current collectors and additional tab welds.
4. Coin Button Batteries: Small, Flat, and Standardized
Coin and button batteries follow an international naming standard that encodes chemistry, diameter, and thickness directly into the model number, making them one of the most systematically organized battery categories. The format is: chemistry prefix (two letters) + diameter code (two digits, in mm) + thickness code (two digits, expressed in tenths of a mm). For example, CR2032 breaks down as: C = Lithium chemistry, R = Round form factor, 20 = 20 mm diameter, 32 = 3.2 mm thickness. LR44 decodes as: L = Alkaline chemistry, R = Round, 44 = a code mapping to 11.6 mm diameter and 5.4 mm height.
Coin cell sizes range from approximately 4.8 mm to 30 mm in diameter and 1.0 mm to 7.7 mm in thickness, covering an enormous variety of low-power devices.Here is a practical selection of the most frequently encountered models:
| Model | Chemistry | Diameter (mm) | Thickness (mm) | Nominal Voltage | Typical Capacity (mAh) | Common Applications |
|---|---|---|---|---|---|---|
| SR512SW | Silver Oxide | 5.8 | 1.25 | 1.55V | ~5 | Miniature watches, hearing aids |
| LR41 | Alkaline | 7.9 | 3.6 | 1.5V | ~25 | Laser pointers, small toys |
| LR44 / SR44 | Alkaline / Silver | 11.6 | 5.4 | 1.5V / 1.55V | ~110–150 | Calculators, digital thermometers, toys |
| CR1216 | Lithium | 12.0 | 1.6 | 3V | ~25 | Car key fobs, small remote controls |
| CR1220 | Lithium | 12.5 | 2.0 | 3V | ~35–40 | Motherboards (CMOS), keyless entry fobs |
| CR1616 | Lithium | 16.0 | 1.6 | 3V | ~50 | Wearable medical sensors, slim remotes |
| CR1620 | Lithium | 16.0 | 2.0 | 3V | ~70 | Garage door openers, security sensors |
| CR2016 | Lithium | 20.0 | 1.6 | 3V | ~75–90 | Watches, slim key fobs, LED flashers |
| CR2025 | Lithium | 20.0 | 2.5 | 3V | ~150–165 | Car keys, calculators, toys, medical devices |
| CR2032 | Lithium | 20.0 | 3.2 | 3V | ~210–240 | PC motherboards, car key fobs, fitness trackers |
| CR2430 | Lithium | 24.5 | 3.0 | 3V | ~270–300 | LED lights, remote controls, glucometers |
| CR2450 | Lithium | 24.5 | 5.0 | 3V | ~600–620 | High-drain remotes, IoT sensors, alarms |
| CR2477 | Lithium | 24.5 | 7.7 | 3V | ~1,000 | Smart home sensors, long-life IoT devices |
The most critical point for anyone replacing a coin battery: same voltage does not mean same fit. The CR2016, CR2025, and CR2032 all share the same 20 mm diameter and 3V nominal voltage, but a device designed for a 3.2 mm-thick CR2032 will not close with a 2.5 mm-thick CR2025, and a slot made for a 1.6 mm-thick CR2016 will not accommodate the thicker model.Conversely, stacking two CR2016 cells (totaling 3.2 mm) in place of a single CR2032 is electrically incorrect—it doubles the voltage to 6V—and can damage the device.
Chemistry also matters significantly despite the shared voltage range. Lithium coin cells (CR-prefix) have a nominal 3V and excellent shelf life, making them ideal for devices that draw power very infrequently (CMOS backup, remote controls). Silver oxide (SR-prefix) delivers a very stable 1.55V discharge curve, preferred in precision watches where voltage stability affects timekeeping accuracy. Alkaline (LR-prefix) offers the lowest cost but a less flat discharge curve and shorter operating life.
5. LiFePO4 Battery Packs & Modules: From Single-Cell to System-Level Dimensions
Individual LiFePO4 prismatic cells are raw components; LiFePO4 battery packs and modules are the finished, often enclosure-housed units that deliver a target system voltage—commonly 12.8V (4S), 25.6V (8S), or 48V (16S)—at a specific energy capacity. The dimensional jump from cell to pack is significant: a 48V 200 Ah module might incorporate sixteen 200 Ah cells plus bus bars, a battery management system (BMS), terminal blocks, communication ports, and a steel or heavy-duty plastic casing, all of which dramatically change the footprint.
Below are representative dimensions for LiFePO4 battery modules in different voltage and capacity classes:
| Module Configuration | Nominal Voltage | Capacity | Dimensions (L×W×H or W×D×H, mm) | Approx. Weight (kg) | Typical Application |
|---|---|---|---|---|---|
| 4S1P (DIY build) | 12.8V | 100 Ah | ~350 × 200 × 220 | ~12–15 | RV house battery, small off-grid cabin |
| 4S2P (DIY build) | 12.8V | 200 Ah | ~521 × 238 × 218 | ~25–30 | Marine house bank, larger solar storage |
| 25.6V 24 Ah module | 25.6V | 24 Ah | 194 × 132 × 170 | 5.7 ± 0.3 | Light electric vehicles, portable equipment |
| 48V 40 Ah module | 48V | 40 Ah | 380 × 380 × 250 | ~35 | Telecom backup, industrial UPS |
| 48V 200 Ah rack module | 38.4V (per module) | 200 Ah | 601.5 × 520 × 135 (per module) | 70 (per module) | Rack-mount solar ESS, scalable to 161 kWh |
For rack-mount energy storage systems, the physical format is often designed around 19-inch server rack standards, with a typical single module height of around 3U (approximately 133 mm). These modules can be stacked vertically. For instance, a system built from 13 modules at 601.5 × 520 × 135 mm each delivers 99.84 kWh of storage capacity, with a total rack footprint of 610 × 610 × 2,350 mm.Smaller industrial modules—such as a compact LiFePO4 pack measuring 165 × 190 × 143 mm delivering 48V at 0.72 kWh—serve automated guided vehicles (AGVs) and portable medical equipment where space on the vehicle frame is extremely tight.
When planning a pack integration, always account for the BMS board thickness (which can add 15–30 mm to one dimension) and the additional space required for cable routing, ventilation, and terminal access. For packs that will be installed in mobile applications (RVs, boats), factor in shock and vibration mounts that add further external clearance.
6. 9V Rechargeable Batteries: A Standard Shape with Internal Chemistry Variations
The 9V battery—often called a “9V block” or PP3-size—is one of the most enduring standard form factors in portable power, used in smoke detectors, multimeters, wireless microphones, guitar effect pedals, and medical devices. Despite the standardized external dimensions, the internal construction varies dramatically between non-rechargeable alkaline, NiMH rechargeable, and lithium-based rechargeable chemistries.
The IEC standard 9V rectangular block measures approximately 26.5 mm wide × 17.5 mm deep × 48.5 mm tall, with the characteristic snap-style connector on top. Typical lithium 9V rechargeable batteries measure approximately 25.5 × 16.5 × 47.5 mm and weigh around 36–40 grams.
Here is a comparison across the three main 9V battery types:
| Chemistry | Nominal Voltage | Capacity (mAh) | Internal Construction | Dimensions (W×D×H, mm) | Weight (g) | Rechargeable |
|---|---|---|---|---|---|---|
| Alkaline | 9V | ~550–600 | 6 × AAAA cells in series | ~26.5 × 17.5 × 48.5 | ~45 | No |
| NiMH | 7.2V or 8.4V (nominal) | 175–300 | 6 or 7 NiMH button cells in series | ~26 × 16 × 48 | ~35–40 | Yes |
| Lithium (Li-ion / Li-Po) | 9V | 500–1,200 | 2 × Li-ion pouch cells + step-up converter or 3S Li-Po | ~25.5 × 16.5 × 47.5 | ~36–40 | Yes |
The key performance differentiator is the lithium rechargeable variant. While NiMH 9V batteries typically deliver only 7.2V or 8.4V nominal, lithium-based 9V rechargeables usually integrate a DC-DC voltage regulator to maintain a stable 9V output throughout the discharge curve. This regulated output is critical for devices like digital multimeters that depend on the battery reference voltage for measurement accuracy.
Lithium 9V rechargeable batteries also offer higher capacity—typically 500–1,200 mAh compared to NiMH’s 175–300 mAh—and a substantially lower self-discharge rate, making them better suited for smoke detectors and other standby applications where the battery sits unused for long periods. The standard pulse current of 7.5 mA and maximum pulse capability of 400 mA covers most consumer applications, including the momentary high-drain bursts needed for wireless microphone transmitters and IoT sensor data broadcasts.
When purchasing, verify that the slightly different dimensions of lithium vs. alkaline 9V batteries do not cause fit issues in your specific device. Some smoke detector battery compartments are molded with very narrow tolerances and may not close cleanly over a lithium rechargeable that is 0.5–1 mm thicker than a standard alkaline block.
7. Portable Energy Storage Power Stations: From Pocket-Sized to Whole-Home Backup
Portable power stations represent the most diverse dimensional category of all, spanning from compact 256 Wh units you can carry in one hand to modular 12 kWh+ systems requiring wheels and handles just to move. These products integrate a rechargeable lithium battery (increasingly LiFePO4), a pure sine wave inverter, multiple output ports (AC, USB-A, USB-C, 12V DC), and sometimes an MPPT solar charge controller—all in a self-contained enclosure designed for transport.
The dimensional spread across different capacity classes tells a useful story for anyone trying to choose the right size station:
| Capacity Class (Wh) | Typical Dimensions (L×W×H or equivalent, mm) | Approx. Weight (kg) | Representative Example | Best For |
|---|---|---|---|---|
| ~250 Wh (ultra-portable) | ~230 × 140 × 140 | ~3.6 | Jackery Explorer 240 | Personal device charging, CPAP backup (single night) |
| ~500 Wh (handheld) | ~268 × 190 × 197 | ~7.5 | Effekta Power-CHEST 500 | Weekend camping, small appliance power |
| ~1,000 Wh (mid-size) | ~286 × 210 × 130 to ~378 × 184 × 240 | ~8–12 | EVE FA0210 (1004 Wh), EcoFlow Delta Mini | Multi-day camping, power tools, emergency fridge backup |
| ~1,000–2,000 Wh (large portable) | ~345 × 228 × 235 to ~520 × 320 × 358 | ~12–22 | Effekta Power-CHEST 1000, Bluetti AC300 (main unit) | Off-grid cabin, extended blackout, field workstation |
| ~2,000 Wh (heavy-duty) | ~385 × 366 × 280 | ~17.5 | Jackery E2000 | Full appliance backup, RV power, construction site tools |
| ~3,800 Wh (near-stationary) | ~630 × 313 × 467 | ~40 | BSLBATT 3,840 Wh station | Whole-home partial backup, long-term off-grid base |
The distinction between portable and non-portable lies not only in weight but also in whether the unit can be effectively carried by one person without mechanical assistance. At around 10 kg, a 1 kWh station is still manageable for one person to lift and carry short distances. Beyond 20 kg, wheels and retractable handles become a near-necessity. At 40 kg and above (3.8 kWh class and higher), these units are functionally semi-stationary and are best treated as installed backup equipment rather than truly portable gadgets.
For expandable modular systems like the Bluetti AC300, the main unit without batteries measures 520 × 320 × 358 mm and weighs 21.6 kg, but each B300 battery expansion module (3,072 Wh) adds approximately 520 × 320 × 300 mm and an additional 38 kg. A fully expanded four-battery system delivers 12,288 Wh of energy storage but demands a permanent floor footprint nearly 1 meter wide.Factor this into your space planning before committing to a modular system.
LiFePO4 chemistry is becoming the dominant battery type in this category for a straightforward reason: cycle life. Where earlier power stations using standard Li-ion cells might reach 500–800 cycles before noticeable degradation, LiFePO4-based stations routinely rate for 3,500+ cycles to 80% capacity, effectively spanning a decade or more of regular use.The trade-off is slightly larger volume per watt-hour compared with NMC-based stations, though the gap has narrowed with improved cell-to-pack integration.
To browse all available models across every capacity class and form factor, check out our product catalog.
8. The Universal Rule: Verify Before You Buy
Across all seven categories, a single rule holds: the datasheet dimension is the nominal dimension. Manufacturing tolerances, protection circuits, terminal types, and enclosure requirements all introduce real-world deviations from the printed number. For cylindrical cells, check whether protected or unprotected cells are specified. For prismatic LiFePO4 cells, confirm that the enclosure accounts for the expected swelling over the cell’s life. For Li-Po cells, verify the tolerance range on thickness—usually ±0.2 to 0.3 mm, which matters more than any other dimension. For coin cells, never substitute a thinner cell for a thicker one just because the diameter and voltage match. For 9V rechargeables, test the fit in your device’s battery compartment before bulk ordering. For battery packs and power stations, always leave clearance for cable routing, ventilation, and connector access.
A dimensional mismatch is the single most common source of returns and refunds in the battery industry—and it is almost entirely preventable. Take the measurement. Check the chart. Then place the order. If you are ready to apply this guide to a real purchase, visit our product catalog for live inventory, detailed datasheets, and dimensional drawings for every battery in stock.