How Xaar’s inkjet technology is transforming EV battery coatings

The electric vehicle (EV) revolution is accelerating, with manufacturers racing to develop more efficient, high-performance batteries. As battery technology evolves, the need for advanced, reliable EV battery coatings has never been greater. Here inkjet – and Xaar – is leading the way with our Xaar eX and Xaar Nitrox eX printheads reshaping the way EV batteries are protected and manufactured.

EV batteries must endure extreme conditions, from high voltages and rapid charging cycles to exposure to heat and mechanical stress. Traditional coating methods, such as PET film, have struggled to meet these demands, often leading to performance inefficiencies and increased material waste.

EV battery coating enabled by Xaar Technology

The developments in inkjet technology are helping to meet the demands of today’s EV battery coating. Xaar’s Ultra High Viscosity Technology allows battery manufacturers to jet advanced functional fluids with viscosities of up to 1000 cP at ambient temperture (100 cP at jetting temperature). This capability enables the development of formulations that provide enhanced EV battery coating performance, including greater mechanical robustness and dielectric strength.

Our unique recirculating TF Technology makes it possible to print in any orientation and ensures reliable coating across all sides, including corners, eliminating the need to reposition the battery during production. Nozzles are also kept clear of unwanted particles and air bubbles, sedimentation is prevented even in highly viscous fluids, reducing the risk of downtime and maintaining high performance levels. Additionally, our High Laydown Technology allows printheads to evenly jet thick coatings in a single pass, improving the overall efficiency of the manufacturing process by avoiding the need for multiple passes.

Optimised for the viscous and challenging fluids required for coating electric car batteries our eX printhead for prismatic styles and Nitrox eX printhead for cylindrical batteries are engineered to tackle the unique challenges of battery coating.

Partnerships in EV battery coating innovation

Our technology is already making waves in the EV battery industry. In collaboration with battery manufacturing companies Shifang Intelligent Manufacturing Technology and Shenzhen Omijia Intelligent Technology Co., our printheads are replacing outdated PET film coatings with high-performance EV battery coatings.

Shifang has cut material costs by 30% and is on track to achieve over 50% savings with mass production. Simultaneously, Omijia is leveraging our technology to enhance lithium-ion battery insulation coatings, meeting stringent safety and sustainability requirements.

These partnerships highlight the impact of inkjet in delivering EV battery coating with the technology reducing costs, improving efficiency and supporting the drive for more sustainable battery production.

Sustainable EV battery coating

Driven by our ESG Roadmap, delivering environmental improvements is a key consideration in our product development and our Innovation pillar. Here, our Xaar eX and Nitrox eX printheads are not only delivering performance and process improvements they are allowing manufacturers to minimise material waste, lower energy consumption and reduce overall production costs. With ink utilisation rates exceeding 99%, inkjet technology is setting new standards for more sustainable battery manufacturing.

Clearly, as the EV industry continues to evolve, so too must the EV battery coating technology that supports it. Our expertise is paving the way for more reliable, efficient and sustainable EV battery manufacturing and is just one of the ways we are driving innovation in manufacturing by unleashing the power of inkjet

Find out more about Xaar’s industry-leading solutions for EV battery coatings here.