ENNOVI is introducing flexible die-cut circuit (FDC) technology as a more advanced and sustainable way of producing flexible circuits for low voltage signals in electric vehicle (EV) battery cell contacting systems.

While flexible printed circuits (FPC) are often employed in these systems, they are the most expensive component in the current collector assembly. ENNOVI’s flexible die-cut circuit (FDC) technology offers a more cost-effective and sustainable solution, with fewer manufacturing procedures and faster continuous reel-to-reel production.

Generally, FPCs are manufactured using a multi-stage, batch photolithography process to etch copper traces for the flexible circuit. This production process uses corrosive chemicals that dissolve the unwanted copper. In addition, it takes a lot of time and energy to extract the waste copper from the chemicals, making it challenging to effectively recycle. The die-cutting process allows for instant recycling of the copper, making it a more substance preference to chemical etching.

Compared with FPCs, which have a size limitation of 600x600mm, FDCs feature no length restrictions as they are manufactured reel-to-reel. Under certain design considerations, the FDC provides similar performance characteristics to FPCs. These results were confirmed through rigorous in-house dimension, thermal shock, trace resistance, temperature rise, insulation resistance and high voltage testing.

Headquartered in Singapore, ENNOVI has more than 10,000 employees across 15 sites globally. The company was launched in 2023 by Blackstone, in partnership with its portfolio company Interplex, a leader in innovative and customized interconnect and mechanical products.