When we talk to battery developers, especially those working with pouch cells, one concern we hear often is this:
“The biggest challenge with pouch cells was always the long lead times and high volume when prototyping with tabs.”
It’s a sentiment we’ve heard repeatedly, and one we’ve actively designed our approach around.
At Avocet Battery Materials, we’ve made it a priority to support prototype-ready pouch cell tabs, without the long wait times or large volume commitments that usually slow development down.
Fast Turnaround for Small Volume Tab Production
We know that getting access to the right tab design early in the development process is key, especially when iterating or scaling up.
That’s why our UK-based production line is set up to:
- Support custom prototype runs of up to 300 pairs
- Offer even smaller-volume dispatch from our stock of pre-designed tab geometries
- Keep lead times short and communication direct
- This helps teams move from concept to testing faster, without committing to quantities they’re not ready for
A Different Approach to Lightweight Design
“How do you make the tabs lighter? Isn’t it just a function of tab aspect ratio and material conductivity?”
It’s a good question (and a frequently asked one), and it’s true that many manufacturers reduce weight by adjusting dimensions or choosing thinner materials. However, with Flyweight, our proprietary bimetallic tab, we take a more material-driven approach.
Flyweight combines copper and aluminium, allowing us to replace the traditional full copper anode tab with a composite structure that offers:
- Significant weight reduction per tab
- The same conductivity where it’s needed (copper-to-copper at the foil stack)
- Improved flexibility in design – we can tailor the copper-to-aluminium ratio to suit the application
This isn’t just about reducing size. It’s about choosing and configuring materials for optimal performance and pack-level weight savings.
If you’re prototyping pouch cells and stuck between long lead times or generic tab options, we’d love to show you how Avocet Battery Materials can support your next phase of development, whether you’re starting small or preparing to scale.
