FibreCoat unveils EV battery case featuring AluCoat aluminum-coated fibers

Source | FibreCoat

FibreCoat GmbH (Aachen, Germany), in collaboration with Forward Engineering (Munich, Germany) and Coleitec (Hangzhou, China), is presenting a novel solution for high-performance composite battery casings for automotive applications.

Traditionally, electric vehicle (EV) electromagnetic-compatibility (EMC) challenges in inverter cases and battery cases are addressed using metal foils, metal plates or sprayed coatings which require additional process steps or exhibit quality and safety issues. Due to the high cost and carbon footprint, nickel-coated carbon fibers are also not a sustainable option.

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FibreCoat’s AluCoat conductive aluminum fiber delivers a cost-efficient, all-in one composite solution, featuring integrated electromagnetic interference shielding (EMC), enhanced fire protection, passive cooling effects, weight and carbon footprint reduction, reduction in production steps and compatibility with existing thermoset and thermoplastic composite (TPC) processes. “This applies to our materials for automotive applications, but also to aerospace, construction and defense,” says Dr. Robert Brüll, CEO of FibreCoat.

FibreCoat’s material technology has been successfully validated under OEM serial production conditions. Multiple prototypes were manufactured at Coleitec’s industrial HP‑RTM line as part of a joint development program, mediated and consulted by Forward Engineering. ​​​​​​

Coleitec’s HP-RTM is a precise, cost-effective method for large-scale battery case production, with very short cycle times. “During HP‑RTM production trials, we saw how AluCoat integrates smoothly into established composite processes while adding real functional value,” says Dr. Bin Wei, CTO of Coleitec. “The passive cooling effect from the aluminum coating on basalt fibers was noticeable as soon as the parts left the press. Combined with the material’s EMC and fire performance advantages, it creates a compelling package for battery housings and other thermally demanding applications.”

A prototype is on display at FibreCoat’s JEC World booth, where the team is sharing more about the innovation and the next steps toward market adoption.

Visit FibreCoat at Booth F104 in Hall 5.