Lithium ion batteries (LIB) are widely used to power electric vehicles. Here we report a comprehensive manufacturing energy analysis of the popular LMO-graphite LIB pack used on Nissan Leaf and Chevrolet Volt. A 24 kWh battery pack with 192 prismatic cells is analysed at each manufacturing process from mixing, coating, calendaring, notching till fi. With the advantages of high energy density, light weight, no memory effect and better environmental performance,, lithium ion batteries are nowadays used for powering all types of electric vehicles (EVs) on the commercial market. Compared with conventional internal combustion engine (ICE) powered vehicles, EVs have a number of technological and environmental advantages: EVs produce zero tailpipe emissions in operations and can reduce the dependence of vehicle operations on foreign oil; EVs also operate quietly and smoothly, have stronger acceleration, and require less maintenance. Due to their superior environmental and societal benefits, EVs are considered the future mode of ground transportation and promoted globally for large fleet deployment in future decades. It is estimated that the global fleet of EVs will reach over 13 million by 2020 and 230 million by 2030, and large fleet deployments of EVs will significantly reduce harmful emissions from the operations of conventional ICE-powered vehicles. As predicted, the EV deployment in 2030 will result in a 20%–69% decline in 2030 greenhouse gas (GHG) emissions from U.S. light-vehicles over 2005 levels.Currently there are three types of EVs on the commercial market : Hybrid EV (e.g. Toyota Prius), Plug-in EV (e.g. Chevrolet Volt) and Battery EV (e.g. Nissan Leaf). Typically, an on-board LIB pack in an EV contains hundreds of single-LI. Prior to the manufacturing energy analysis of lithium ion battery, here we first present detailed material compositions of the 24 kWh lithium ion battery pack, and then provide a description about the actual battery manufacturing processes at an industrial scale for subsequent manufacturing energy analysis.Here a detailed unit process energy analysis of lithium ion battery manufacturing is presented, through direct measurement of the energy data using HOBO UX 120-006M data loggers and Onset CTV-A current meters on Johnson Controls' pilot scale dry room production facility. The dry room is heated by one heat coil with a power demand of 31.8 kW and one. In this study, we have conducted a unit process level energy analysis for lithium ion battery manufacturing for electric vehicles, based on directly measured data of a pilot scale industry production facility. Detailed manufacturing processes are presented along with material flows for manufacturing a 24 kWh LMO-graphite lithium ion battery pack. T.