As performance demands in energy storage continue to rise, weight is becoming the next frontier, especially for applications in aerospace, motorsport, EV, eVTOL, and defence. At Avocet Battery Materials, we’re focused on solving this challenge from the inside out, starting with one of the most overlooked contributors to pack weight: the cell tab.
This October, we’ll be at The Battery Show North America (October 7–9) showcasing our innovative solution: Flyweight, a proprietary bimetallic lead tab that delivers substantial weight savings without compromising on performance.
What Is Flyweight?
Flyweight is a bimetallic lead tab for pouch cells designed to significantly reduce the weight of battery packs by replacing most of the copper traditionally used in tabs with aluminium, while still maintaining copper-to-copper welding at the foil stack and aluminium-to-aluminium at the module level.
Key benefits include:
- Weight reduction of up to 5.63 kg per 1000-cell pack
- Stable surface treatment, ideal for corrosive or high-performance chemistries
- No adhesives or welds used in joining copper and aluminium, preserving electrical conductivity
- Edge tapering to support full sealing, even with thicker tabs (>1 mm), enabling high power and fast-charging applications
- Customisable to each cell/module design
- Scalable for production in demanding industries
Flyweight is already in use in projects where performance is critical and every gram counts, from racing EVs to aerospace systems.
Why It Matters
In markets like EV, aviation, and defence, every design decision must balance performance with efficiency. The humble cell tab may not get much attention, but across hundreds or thousands of cells, the weight adds up quickly. Flyweight solves that problem at the component level, helping OEMs and battery developers meet their energy density, range, and integration goals.
At Avocet Battery Materials, we specialise in pouch cell tab manufacturing and work with customers around the world to engineer tabs that fit both the technical spec and the real-world application.
Visit Us at The Battery Show North America
We’ll be exhibiting at Stand 3222 (UK Pavilion) from October 7–9, showcasing Flyweight and discussing how Avocet Battery Materials can support your next-generation cell development.
You can pre-book a meeting with us here.
Whether you’re an OEM, cell manufacturer, research institute, or integrator, if your battery needs to do more with less, let’s talk.
