If we use 4mm (it looks like that's a high number) for the space saved by the stagger instead of 81 (9 x 9 x 20mm) vs (10 x 10 x 18mm) we would have (9 x 9 x 16mm) vs (10 x 10 x 18mm). 9 x 16 = 144, and 10 x 14 = 140. Almost the same number.
Endless-sphere.com • View topic - Tesla Model S 18650 Cell Test Data
I don't see why they would need to increase the space, so the overall density of the pack won't change that much e
xcept for the height.
1. The correct number is 7.6%, and the total will be very close to the same.
2. The effect of the extra radius will be negligible at the pack level. About 20% more capacity per cell, but close to the same reduction in the number of cells.
3. Between these things you can get up to a maximum of about an 10% extra active material in the pack.