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Optimizing the Design of Die-Cut Battery Components to Reduce Waste and Manufacturing Costs

With costly redesigns, delayed EV adoption, and dangerous product failures on the line, balancing product performance and manufacturing costs can sometimes feel like a losing game. Luckily, with the strategic implementation of a few key design for manufacturability and assembly (DFMA) principles, you can optimize the design of your part to help reduce waste without affecting part performance. The goal of this blog is to arm you with some actionable DFMA tips that you can leverage the next time you are designing a die-cut EV battery or energy storage component to help reduce waste and manufacturing costs.

The Role of Electrical Insulation in High-Voltage Battery Energy Storage Systems

Grid-level energy storage applications handle massive amounts of electricity that many communities rely on day in and day out. In these high-voltage applications, proper electrical insulation is paramount for battery safety, performance, and longevity. In this blog, we're taking a look at the critical role die-cut electrical insulation materials play in preventing electrical arcs, short circuits, and dangerous thermal runaway events, as well as a high-level overview of some important industry standards and material testing methods.

Die-Cut Cell Separator Materials: Optimizing Safety and Performance for EV and BESS Battery Packs

Cell-to-cell propagation protection is more than just preventing thermal runaway, electrical shorts, and vibration damage, it's the key to optimizing battery safety, longevity, and overall product performance. In this blog, we're taking a look at die-cut battery cell separators for EV and BESS battery packs, highlighting some common cell spacer materials and diving into what makes a good cell divider for your specific battery application.

Die-Cut Aerogel Alternatives for Mitigating Thermal Runaway in Battery Applications

Thanks to their lightweight, thermally insulative properties, aerogels have long been a popular solution for thermal runaway mitigation in battery packs. However, the handling concerns associated with aerogels, coupled with their high price tag, has battery manufacturers looking for high-performance alternatives. In this blog, we're highlighting four die-cut stand-ins for aerogels that provide thermal runaway mitigation in a lightweight, affordable package.

Battery Material Spotlight: 3M™ FRB-NT Insulating Paper

3M™ FRB is a family of high-performance insulation material engineered for a range of different applications. The lower density and laminated variants of the FRB-NT family offer solutions to various issues within the E-Mobility sector, mainly providing electrical insulation and cell-to-cell propagation protection for battery packs.

Performance Materials for Thermal Management in Battery Applications

OEMs are hard at work hunting for the EV battery thermal management unicorn. But no single material or process has emerged as the clear leader.  Thermal Management materials are typically produced in large rolls or sheets and must be transformed into custom solutions by a specialized converter that can combine base materials, then cut and package the material to be ready for use by the battery module and pack manufacturers. This paper highlights several key thermal management materials and discusses how JBC Technologies fits within the EV battery manufacturing value chain.