Flexible Printed Circuits (FPCs) are traditionally used in EV battery cell contacting systems, but they are often the most expensive component in the current collector assembly. FPCs are manufactured through a complex, multi-stage, batch photolithography process to etch copper traces for the flexible circuit.
A major environmental drawback of this traditional method is that it uses harsh, corrosive chemicals to dissolve the unneeded and excess copper. Consequently, this process is both time- and energy-consuming. Furthermore, FPCs manufacturing makes copper recycling difficult.
How Does Flexible Die-Cut (FDC) Technology Provide a Superior Alternative?
Flexible Die-cut Circuit (FDC) technology is a more cost-effective and sustainable alternative that replaces the chemical etching of FPCs with a continuous, reel-to-reel mechanical die-cutting manufacturing process. This method produces a flexible, flat device featuring copper traces created through a sustainable manufacturing path that involves fewer processes.
Contrasted with traditional photolithography, FDC technology provides high-precision die-cutting that results in tight tolerances without chemical waste, while its continuous copper traces provide a reliable signal.
What Efficiency Gains Can Manufacturers Expect by Switching from FPC to FDC?
Switching from FPCs to FDCs delivers major efficiency and financial advantages. With FDC, cost savings of up to 50% are achievable without compromising on technical capabilities and performance. Furthermore, manufacturers can realize a 50% reduction in production process time by eliminating multiple manufacturing steps compared to its printed counterpart.
This reduction comes from a simpler and more efficient production process. Creating an FPC requires 12 process steps, while creating an FDC only requires 9. More importantly, the 3 steps eliminated in FDC involve chemical etching, which are among the slowest and most costly parts of the process.
In FPC production, chemical etching is batch-oriented and requires dwell time during drying, exposure, and etching. As a result, this stage can take 2–3 days to complete. In contrast, FDC uses a continuous precision die-cutting process, which removes these delays and helps accelerate overall production.
The comparison below shows the key differences between the two processes:
| FPC | FDC | |
| Copper Layer | Chemically Etched | Die Cut |
| Minimum Trace Width | 0.25mm | 0.35mm |
| Minimum Trace Pitch | 0.30mm | 0.35mm |
| Laminate Layer | PI, PET, or PEN | PI, PET, or PEN |
| Cost | Higher | Lower |
| Cycle time | In batches | Continuous |
| Recyclability | NA | Yes |
Beyond process efficiency, manufacturers can also benefit from design flexibility. Our FDC approach supports traces with a diameter of 0.35 mm and above, and both the size and trace design can be easily customized for diverse end applications.
Why is FDC Considered a More Sustainable Choice for Low-Voltage Signals?
FDC is considered a more sustainable choice for low-voltage signals because the die-cutting process enables the instant recycling of clean copper waste material directly from the line. This effectively eliminates the need for the energy-consuming chemical recovery processes and environmental challenges associated with traditional FPC etching. Ultimately, this process embraces sustainability and makes ENNOVI’s FDC technology ideal for supporting a myriad of low-voltage solutions while maintaining a lower impact on the environment.
Transitioning to Clean, High-Speed FDC Manufacturing
Flexible die-cut circuit (FDC) technology is a more cost-effective and sustainable alternative for producing flexible circuits for low voltage signals in EV battery contacting systems. Our FDC approach is suitable for traces with a diameter of 0.35mm and above. The size and trace design can be customized for your end applications.
Our goal is to ensure that the designs are technically sound and economically viable for mass production. By participating from the early stages, we help our customers refine their concepts into practical, manufacturable solutions that align with both their performance and budgetary requirements.