Expanding EV Market Drives Shift Toward Production Efficiency Optimization
As of August 2026, the global electric vehicle (EV) fleet has surpassed 60 million units. With the market continuing to expand, EV manufacturers and battery suppliers are no longer focused solely on technical feasibility but must also ensure quality, safety, and profitability at scale. In this context, pressure-sensitive adhesive (PSA) tapes, a mature process material, are increasingly becoming a critical solution for simplifying battery production workflows and enhancing automation levels.
PSA Tapes Replace Traditional Methods, Eliminating Curing Time and Equipment Investment
Avery Dennison Performance Tapes has developed Volt Tough™ Stretch, a PSA tape specifically designed for battery insulation. The tape can be directly applied to metal plates before cutting and stamping. Unlike traditional powder coatings or liquid adhesives, PSA tapes require no curing time, allowing immediate progression to the next production step and eliminating capital expenditures such as curing ovens. Max VanRaaphorst, Market Manager for Energy Storage at Avery Dennison Materials Group North America, stated that the product’s built-in stretchability effectively prevents dielectric barrier damage during stamping, making it suitable for automated or robotic production lines.
The advantages of PSA tapes extend beyond process simplification. Compared to liquid adhesives, which require curing time, or mechanical fasteners, which increase part count and weight, PSA tapes enable instant bonding, reducing the risk of component displacement. This is particularly beneficial for the precise assembly of multi-layer battery components. Additionally, tape substrates such as PET film maintain dimensional stability during high-speed robotic operations, improving positional accuracy, while foam or non-woven facestocks provide flexibility on irregular surfaces, meeting the demands of automated production.
Reducing Damage to Fragile Materials and Enhancing Production Yield and Cost Efficiency
Battery production often involves fragile materials like mica or ceramic paper, which are prone to cracking or delamination due to excessive mechanical stress on automated production lines. Avery Dennison mitigates this risk by adjusting the release force of liners (low, medium, or high) or employing zone-coated adhesives. Furthermore, PSA tapes can be paired with printed liners or pigmented adhesives to integrate with vision inspection systems, enabling early defect detection and preventing waste in subsequent processing steps. VanRaaphorst noted that these incremental improvements accumulate significant benefits in large-scale production, effectively increasing yield and reducing manufacturing costs.
The applications of PSA tapes are not limited to bonding. Through customization, tapes can integrate electrical insulation, flame barriers (such as mica), or cushioning foams to meet the electrical, thermal management, and shock absorption requirements of battery packs. Avery Dennison emphasizes that early collaboration with battery manufacturers allows for the development of tailored solutions to address specific design challenges, such as varying substrate and tolerance requirements for modules and battery packs. While the company has partnered with multiple EV manufacturers and suppliers to integrate PSA tapes into production lines, it has not disclosed specific customer names or quantified performance data.
Technology Validation and Market Outlook: PSA Tapes Emerge as a New Trend in Battery Manufacturing
Although the advantages of PSA tapes in battery manufacturing have gained initial industry recognition, their long-term durability and real-world mass production performance still require further validation. As the EV market continues to expand, manufacturers’ demands for cost reduction and efficiency improvements grow increasingly urgent, drawing attention to the application prospects of innovative materials like PSA tapes. Avery Dennison plans to host an online seminar in September 2026 to share additional application cases and technical details but has not yet released specific performance data.
EV battery manufacturing is facing unprecedented challenges in scaling production. As a mature and flexible solution, PSA tapes are gradually becoming a key tool for manufacturers to optimize production processes and enhance competitiveness. With ongoing technological advancements, PSA tapes are poised to play an even more critical role in battery manufacturing, delivering more efficient and reliable production methods to the industry.
