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Powdertech’s seminar at Battery Tech Expo, 2025

Powdertech Surface Science 08/04/2025

On March 27th, 2025, our Technical Manager, Dr. Nick Welton, delivered an insightful presentation at the Battery Tech Expo titled "From Busbars to Battery Enclosures—Evolving an Established Technology." Dr. Welton, with nearly 40 years of experience in aluminium surface finishing and a PhD in Polymer Chemistry, shared his expertise on advancing dielectric coating technology for aluminium battery enclosures in electric vehicles (EVs).

Powdertech's Technical Manager Dr. Nick Welton with Powdertech's Marketing and Sales Manager Jimmy Phillips

Technical Manager Dr. Nick Welton and Marketing and Sales Manager Jimmy Phillips at Battery Tech Expo.

Dielectric coating is a proven technology for insulating copper busbars. However, applying this technology to aluminium components in EV battery enclosures presents unique challenges due to the distinct properties of aluminium. Dr. Welton discussed the evolution and adaptation required to address these challenges, emphasizing the importance of:

Fit Tolerance: Ensuring the coating is thick enough to meet the specific requirements of OEMs. Coating if too thick will affect fit tolerance and thermal performance.

Edge Coverage: Achieving consistent coating thickness on edges, as sharp and irregular edges are more prone to coating failures.

Porosity: Preventing the presence of air, holes, or bubbles within the coated layer, which can affect the coating's integrity.

At Powdertech Surface Science, we distinguish ourselves through:

In-House Technical Expertise: Our PhD-qualified industry experts oversee sample processing, utilizing advanced testing equipment like XRF and INSTRON to ensure quality.

Comprehensive Services: In addition to surface treatments, we offer sub-assembly processes, direct dispatch to OEMs, and 100% component inspection on behalf of Tier 1 suppliers.

Research Projects: We participate in and often lead UK and EU-funded projects as the surface treatment partner, contributing to initiatives like the APC ALIVE project, Innovate UK-OPTIMA, Niche Vehicle Network - SOLMAC, and to more such research and development programmes.

For a summary of the seminar highlights and to learn more about how Powdertech is overcoming dielectric coating challenges in EVs, while ensuring top-tier quality control, watch the conversation between our Marketing and Sales Manager, Jimmy Phillips, and Dr. Nick Welton.