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charging ev battery with connective die cut parts
Lee K. HouseApr 10, 20244 min read

5 Types of Die Cut EV Battery Solutions

When your eyes ache from staring down a whiteboard, it’s time to consider alternative solutions.

As the market for electric vehicles rapidly expands, so does the demand for innovation in EV batteries. For instance, Strouse constantly looks for new ways to construct and die cut challenging connective parts for EV batteries.

If you’re involved in making EV batteries, take a seat— these five applications will help you understand the primary uses of die cut adhesives.

5 Die Cut Applications for EV Batteries

EV batteries often consist of cells bound in modules that combine to form a battery pack. Therefore, EV battery construction involves many surface areas and connections between dissimilar materials.

Die cut parts can:

  • Bind cells and modules together
  • Insulate individual components
  • Shield from EMI
  • Provide gasketing/battery protection
  • Reduce thermal runaway


Die cut tape can be a rapid assembly aid and immediate bonding solution for EV battery applications. Double-sided die cut tape also contains multiple substrates, allowing you to join dissimilar materials.

Manufacturers can instantly bond tiny components or entire panels of material using die cut parts because die cut tape is lightweight, precise, and facilitates immediate bonding.

  • Liquid adhesives take longer to set than adhesive tape (which holds instantly on contact) and are difficult to apply precisely. 
  • Mechanical fasteners (like bolts, screws, or rivets) are heavy and at a higher risk of metallurgical contamination and rust. 

Surface connections between cells and modules are often between different materials, such as ceramic and mica, which is where double-sided tape comes in. For instance, Strouse built a solution for Tesla Motors to attach multiple layers of mica during the EV battery assembly process. 


Electrical insulation involves wrapping conductive components within the EV battery to prevent arcing or shorting. The protective die cut parts form a material barrier to separate the different layers and stop misconnections from harming the battery.

EV manufacturers use single or double-sided tapes for cell insulation:

  • Single-sided tape can attach to dielectric strength parts or materials, which are often ridged and geometrically complex. 
  • Double-sided tape combines compression pads and panels to maximize the insulating effect. 


EMI and RFI shielding involves applying die cut layers to EV cells or modules to prevent electromagnetic interference from disturbing other vehicle apparatuses such as the main display, radio, or backup camera.  

Electric vehicles host many onboard systems for safety, navigation, and fueling, but interference from the EV battery can cause these systems to malfunction

Die cut EMI shielding parts are typically made from materials like copper and aluminum, and you can find them in the form of EMI gaskets, films, or foils. These pieces cover whole surfaces to avoid signal leakage, and their application method is highly precise. 


Moisture and other contaminants can devastate an EV battery, so a tight seal is crucial for any assembly. Many manufacturers use die-cut gaskets to prevent moisture from reaching the electrical battery components. 

Many electric vehicles contain dielectric liquid cooling systems and other fluids that could cause significant damage given a leak. Leaks in the battery pack can harm the internal components, reducing the battery’s lifespan and increasing the risk of failure. 

Die cut gaskets inside batteries fill gaps and seal off the electrical parts. Converters often use flame-resistant material to build EV battery gaskets for added protection in case of thermal runaway. 


EV batteries have the potential to overheat, which can cause catastrophic damage to the electric vehicle. If one individual cell is damaged and starts burning, the fire might spread to other cells and create thermal runaway. 

Thermal runaway is the worst-case scenario for an EV manufacturer. Once the excess heat has escaped the cell, it can result in burning, melting, and explosions: not ideal for any driver. 

As a result, many batteries use die cut parts to protect the individual cells from thermal runaway by bonding cells to composites that reduce the risk of total failure. 

Using materials like flame-resistant PETs or polyamides, flexible material converters create die cut parts to help contain thermal runaway. 

How Die Cut Parts Elongate EV Battery Life

EV batteries are full of delicate components that require effective, lightweight connections to ensure healthy battery life. 

By keeping components bonded, insulating and padding against physical damage, shielding from interference, trapping out moisture, and reducing thermal runaway for battery protection, die cut parts elongate EV battery life. 

Where to Start: Die Cut Applications

Now that you’ve read more about EV battery die cutting solutions, it’s time to bring your design to fruition. But with so many different companies and materials, how can you get started?

If you’re planning to design EV battery components, you’ll want to discuss your plans with a converter to prove out concept and find the right material and process. 

Reach out to a converter for samples today, and you can test out your part with suitable material to see whether it’ll add value to your EV battery design. 



Originally published: February 20, 2023


Lee K. House

Copywriter & Content Creator for Strouse. Lee graduated from the University of Alabama in the Spring of 2022 with a double major in English and Spanish.