With fuel prices rising, battery costs are among the few remaining barriers to EV adoption. Even though lithium-ion battery packs now cost 90% less than they did 15 years ago, many businesses still struggle to assemble them cost-effectively.
Here’s why working with an adhesive converter makes a difference.
Adhesive converters, such as Strouse, manufacture EV bonding, sealing, and gasketing solutions tailored for efficient battery assembly.
This is how a reliable converting partner will help reduce costs and improve battery capacity.
Given the current market's uncertainty and a potential influx of lower-quality EVs, it is now more crucial than ever to design a sustainable battery model that competes on range, cost, and reliability.
Converted parts will reduce battery costs for multiple reasons.
Although spray coating and other glues may seem cheaper at first glance, they require drying. Unlike liquid adhesives, pressure-sensitive adhesive gaskets bond instantly, eliminating drying time and accelerating application.
Adding tabs, crack-and-peel liners, and other converted features to certain part components, such as EV battery gaskets, can reduce assembly costs.
You might build first-generation batteries by hand, but as you develop the next gen, you move into automation, which has different requirements. Converters can also help format your product components for automation, enabling a faster, more precise production process.
Battery quality is of the utmost importance when you’re building to prevent the catastrophic effects of thermal runaway.
Spraying flat, complex, and accurate shapes can be challenging and often results in overspray; die cut parts fit precise shapes and reduce application errors that can result from the messy, imprecise process of spray coating.
Adhesive tapes often offer multiple uses beyond bonding; for this reason, die cut EV parts can improve battery life in a multitude of ways:
Consumers yearn for an affordable electric vehicle, largely in part because the taste of rolling debt has left a sour taste in their mouths. By the end of 2025, more than 29% of vehicle trade-ins had negative equity, meaning owners owed more than the vehicle was worth. To increase EV adoption, EV battery costs and driving ranges must align with market needs.
Because the electric vehicle market is rapidly growing, global leaders are rigorously adjusting policies surrounding EVs to the benefit or detriment of manufacturers.
In 2025, while other countries signed policies to promote EV adoption, U.S. President Donald Trump signed the 'Big Beautiful Bill', eliminating tax breaks that had helped lower the costs of electric vehicles and EV home chargers. Earlier that same year, New Jersey’s ‘Electric and Hybrid Vehicle Management Act’ made it illegal to dispose of EV batteries in landfills to promote battery recycling.
Your design and the overall construction play a pivotal role in the costs related to your battery. Here are some questions that you should tackle before moving to production:
All these elements will influence battery costs, from press run speed to the required level of quality management.
Despite rising material costs, the price of lithium-ion batteries has steadily declined due to increased global manufacturing capacity. In some ways, you can expect the same from your converted components—ordering larger quantities will unlock material-tier pricing discounts and spread machine setup labor costs across more products.
Companies partner with converters for a multitude of reasons:
Experienced converters will guide you through design adjustments, material sourcing, prototyping, and manufacturing to help you get the best value.
Strouse’s team will help create a high-value solution tailored to your application. We will use thorough process planning and reliable manufacturing methods to optimize your production process.
Still unsure? See the die cut EV battery solutions we offer.
Originally published: November 14, 2025