It’s been a big year for Flyweight, our bimetallic tab for pouch cells and we’re proud of the progress it’s made.
Created by Avocet Research Centre (ARC) and manufactured by Avocet Battery Materials (ABM), Flyweight was made to solve a clear challenge: reduce the weight of battery tabs without compromising performance. And it’s done exactly that, proving itself in real-world applications across EV, aerospace, and defence projects, with strong interest from some of the most advanced battery developers in the world.
What Makes Flyweight Different?
Flyweight replaces most of the copper in a standard tab with aluminium, while still maintaining copper-to-copper welding at the foil stack and aluminium-to-aluminium at the module. This means you keep conductivity where it matters, and lose the weight where you can.
Depending on the size of the tab and the number of cells in the system, the weight savings can be substantial. In one recent example, Flyweight reduced the overall battery design weight by more than 100 kg.
Even in smaller pack formats, the difference adds up, for instance, replacing a 10 g copper tab with a 4.4 g Flyweight tab could save over 5 kg in a 1000-cell system.
Key advantages include:
- Significant system-level weight reduction
- No adhesive or weld joining the metals – electrical integrity stays intact
- Edge tapering for full sealing, even on tabs over 1 mm thick
- Built for high power, high current, and fast charge environments
- Manufactured in the UK, with customisation available
It’s already being used in weight-sensitive applications where size and performance both matter.
A Word From Our CEO
Kieren Hall-CEO of Avocet Materials Group
“Flyweight has done more than we expected. It started as a product idea, and it’s now a real competitive advantage for the companies using it,” said Kieren Hall, CEO of Avocet Battery Materials. “It’s exciting to see a tab we’ve developed go from prototype to production, and we’re just getting started.”
Why It Matters for Pouch Cell Tabs
For many of our customers – whether they’re building drones, EV packs, or aerospace systems – pouch cells offer flexibility and energy density. But the tab is often overlooked. With Flyweight, we’ve shown that pouch cell tabs can be engineered to support the performance of the full system, without adding unnecessary weight or complexity.
