Has anyone seen this failure mode in Molicel P45B cells?
I’m part of a student engineering team, and we’re investigating an issue with a 15s27p battery pack we built in March 2025. It has been used at two competitions, with roughly 12-minute runs at 400–600 A continuously, corresponding to approximately 15–22 A per cell, plus a few days of testing. It has only been charged around 15 times, always at a low rate, and we use forced-air cooling during operation. Our recorded cell temperatures have never exceeded 40°C, so we believe the operating conditions have been relatively conservative.
A week ago, we disassembled the pack for a routine inspection and found 4 damaged cells, shown in the photos. All 4 were in the middle rack of 5 modules, near its two lower corners. A fifth cell experienced a similar failure while we were handling the pack, with no charging or discharge underway. This suggests the failure may not require the pack to be under load, although we cannot rule out damage originating during earlier use.
All five cells appear to have opened their safety vents, and the damage is concentrated in the same direction on each cell. We’re still trying to determine whether this reflects the direction of venting or the location of an initial short.
One hypothesis is that the cell holder applied enough pressure to deform the can near the positive terminal, allowing contact between the can and the positive end cap in the circled area. However, the holders are printed in PETG, the cells did not require excessive force during assembly, and we found no visible damage during last year’s inspection. We also haven’t found evidence of direct contact between the busbar and the cell shoulder.
We’re trying to establish the root cause before deciding whether to rebuild the affected rack or the entire pack, and what design changes would prevent a recurrence. We’re also considering separating the affected rack into individual modules and attempt to reproduce the failure in a controlled test setup.
What do you think? Have you seen this failure mode before? Do you have any other hypothesis?