PSA Tapes Cited as Strategy to Optimize EV Battery Manufacturing

As the global electric vehicle fleet surpasses 60 million units, manufacturers are shifting focus from proving feasibility to ensuring manufacturability. A new report highlights pressure-sensitive adhesive (PSA) tapes as a key tool for optimizing battery production processes.

What Happened

According to a whitepaper by Max VanRaaphorst, sponsored by Avery Dennison Performance Tapes, PSA tapes offer a mature technology alternative to liquid adhesives and mechanical fasteners. These tapes feature one or two adhesives that bond upon light pressure, a facestock for dimensional stability, and a protective liner. Unlike liquid adhesives, which require cure time and exhibit application variance, PSA tapes allow for clean, repeatable application and immediate movement to the next production step. This capability supports automated processes, including pick-and-place of die-cut parts and wide-web lamination.

Why It Matters

The shift toward scalable manufacturing requires reducing scrap, complexity, and capital expenditure. PSA tapes address these challenges by eliminating the need for curing ovens, thereby reducing CAPEX and production time. The report cites Avery Dennison’s next-gen Volt Tough Stretch tape as an example; it is engineered to adhere to flat metal blanks before they are stamped, preventing tearing or cracking during formation. This contrasts with traditional dielectric strategies like powder coating, which can add complexity and cost. Furthermore, tapes can be customized with electrically insulative films, flame barrier materials like mica, or shock-absorbing foams to enhance safety and performance without increasing part count or mass significantly.

The Bottom Line

PSA tapes provide a design-for-manufacturability solution that simplifies battery assembly, supports robotic automation, and reduces production costs by eliminating cure times and minimizing damage to fragile components.