Well the innovations keep ticking over here at Voltron Motorcycles
I have been trying to find a way of using high energy density LiPo in very large capacity packs. The biggest pack I can conveniently solder is 5p, or 25 Ah. Depending on the cells you use, this could mean discharge currents as high as 700 amps! Nonetheless, lower C-rate cells in large formats are ideal for cars and low voltage motorcycles, but soldering 12 cells together in one hit is really hard - and the odds of a lacklustre cell bringing down the group are higher (there's more of them).
You might recall I had devised a termination system for EIG cells using M3 screws and water jet-cut busbars. Well I am considering this for the LiPo packs. It requires being able to hole-punch the tabs of the cells as accurately as possible, which might be a tough ask. But with the right jig, I reckon you can make a go of it.
I took one of my 7s2p boards for the 40C cells from Herewin. This has the BMS trace from the inner busbar pad extended out for a neater assembly. I drilled some 3.2 mm holes and soldered a couple of brass nuts to the underside. Then I took a LiPo cell which hadn't had it's cell tabs trimmed and punched some ~4 mm holes (it's imperial, so who TF knows) to account for any misalignment and screwed a bit of 2 mm busbar down onto the PCB.
I think it's a winner! I personally wouldn't do this for 2p or 3p boards because the soldered busbars give a much better connection. But for 4p and bigger, or situations where you're not demanding too much from the cells because the capacity is already 40 Ah or so, it's a pretty neat solution. It also gives you a decent screw terminal to mount balance wires to, if you want really high balance currents or just find it more convenient. Otherwise the solder pads are still accessible.
So I will be experimenting with a few cell formats. At least if you don't want to screw terminate, you can still solder them as before. These cells are 9 mm thick, so there's plenty of real estate. If the cells were 7 mm thick, it's a bit tighter, but provided they were all in parallel I can't see an issue with potential shorts.