tesa at The Battery Show 2025: Integrated innovation in EV battery production

How the German company is advancing adhesive and insulation technologies to support safer, smarter and more sustainable manufacturing.

As electric vehicles evolve, the demands on battery technology continue to grow – particularly in the areas of electrical safety, mechanical stability, repairability and production efficiency. According to German brand tesa, adhesive solutions are increasingly at the center of this transformation, playing a critical role in ensuring performance, durability and sustainability.

At The Battery Show Europe 2025, 3 to 5 Juni 2025 in Stuttgart, Germany, tesa is showcasing a portfolio of advanced adhesive technologies that address these challenges through process integration, multifunctionality and smart separability.

The company’s latest innovations include a structural electrical insulation system, reversible bonding technologies and re-openablesealing solutions – all designed based on the high standards of automotive and battery production.

Integrating insulation and structure in a single step

One of the highlights of tesa’s current portfolio is a multi-functional insulation and bonding material that delivers electrical insulation and mechanical reinforcement in a single lamination step. This solution addresses several industry-critical demands simultaneously.

The material offers excellent dielectric strength, effectively insulating even around the complex geometries and sharp contours typical for cells and sideplatesar. At the same time, its mechanical bonding capability contributes to crash performance and overall structural integrity.

Where this solution stands out is its compatibility with existing wrapping and lamination equipment. Manufacturers can integrate it without redesigning their production lines, making it an attractive choice for those pursuing higher efficiency for more compact battery pack designs. The system supports both performance and sustainability goals by reducing process steps, minimising material waste and enabling modular construction.

A partner network supporting customisation and scalability

Recognising that battery designs vary significantly between global regions, OEMs and technologies, tesa heavily engages in partnerships with scientific institutes, car, battery and part manufacturers as well as production equipment manufactuers.

tesa also leverages its global network of certified converter partners to offer tailored solutions. These converters, several of whom are exhibiting at the show alongside tesa, provide custom die-cut formats and roll-to-part configurations. This ensures that tesa’s materials are not only technically advanced but also production-ready, scalable and adaptable to a wide variety of applications – from cell wrapping to interlayer insulation and EMI shielding.

For converters, this approach highlights an opportunity to deliver greater value through precise formatting and just-in-time delivery, bridging the gap between material science and production-floor execution.

Debonding on Demand technology

In parallel with its work on structural bonding, tesa is advancing the field of Debonding on Demand technologies – a new generation of adhesive tapes that provide strong, durable bonds during operation but can be cleanly separated when needed. This technology is built for circular product design and supports repair, reuse and recycling initiatives. Adhesive tapes with Debonding on Demand technologies can be de-bonded and removed without damaging substrates. Designed to withstand heat and aging, they are suitable for bonding battery modules, covers, or components where disassembly may be required later for servicing or recycling.

Use cases include in-line manufacturing rework, the replacement of faulty modules and the recovery of high-value components for second life purposes – all contributing to material efficiency and reduced scrap rates.

Robotic application of sealing tape for battery boxes

Battery enclosures require reliable environmental protection, but traditional sealing methods can be slow, messy, or difficult to rework. tesa’s ACXplusBoxSeal tape, addresses these challenges including and automated "endless" application process.

Designed specifically for sealing battery boxes, this tape offers:

• Fast, clean application with no curing time
• High resistance to dust, water and thermal cycling
• Re-openability and resealing, allowing for inspection and repair
• Full compatibility with robotic systems, supporting modern assembly environments

At the show, this tape is being applied in a fully automated demonstration using a collaborative robot, illustrating its production-line readiness and suitability for high-throughput environments.

Forward-thinking materials for a demanding market

tesa’s current portfolio reflects a broader trend toward integrated functionality in adhesive products – where a single material must perform multiple roles in a demanding environment. For OEMs, converters and battery manufacturers alike, this shift presents both a technical opportunity and a logistical challenge. tesa’s strategy of combining material innovation with a strong converter ecosystem positions it to deliver solutions that are both advanced and adaptable.

As EV battery systems become more compact, modular, and recyclable, adhesive technologies will continue to serve as critical enablers of product innovation. With a focus on integration, reversibility, and automation, tesa’s offerings aim to support the next generation of electric mobility – not just in performance, but in manufacturability and end-of-life strategy.

Caption: As electric vehicles evolve, the demands on battery technology continue to grow – particularly in the areas of electrical safety, mechanical stability, repairability and production efficiency. (Images: tesa)

Source: tesa

www.tesa.com