A review of cell-to-body (CTB) battery-structure integration design for electric vehicles

The automotive industry is undergoing a profound transformation toward electrification, with battery electric vehicles (BEVs) emerging as the dominant solution for sustainable transportation. Among the critical innovations driving this transition, Cell-to-Body (CTB) technology represents a paradigm shift in battery system architecture, fundamentally redefining the relationship between energy storage and vehicle structure. This review examines the structural design principles, mechanical performance characteristics, and engineering challenges associated with CTB integration. By analyzing recent developments from industry leaders including BYD’s Blade Battery CTB system and Tesla’s structural battery pack, this paper provides a comprehensive overview of the technological evolution from conventional Cell-to-Module (CTM) configurations toward full structural integration. The discussion encompasses topology optimization strategies, crash-worthiness considerations, thermal management integration, and manufacturing implications. Furthermore, this review identifies critical research gaps and future directions for advancing CTB technology in next-generation electric vehicles.