The push toward electric vertical take-off and landing (eVTOL) aircraft has brought major advances in propulsion, materials, and system integration. But high-performance flight demands more than just power, it demands precision at every layer of the battery.
One of the most overlooked components in this equation? Pouch cell tabs.
At Avocet Battery Materials, we design and manufacture pouch cell tabs that meet the specific challenges of the eVTOL sector, where space, weight, and reliability must be tightly controlled.
The Challenge: Weight, Heat, and Reliability
EVTOL batteries operate under tough conditions. High discharge rates, limited space, and strict certification standards mean there’s very little margin for error.
Traditional nickel-plated copper tabs can add significant mass to a pack, especially when multiplied across hundreds of cells. They can also contribute to localised heating if not properly matched to the application.
And because most eVTOL designs are still evolving, many programmes need cell tab suppliers who can adapt quickly, without requiring huge volumes or long lead times.
Our Solution: Lightweight, Application-Driven Tab Design
We supply pouch cell tabs for eVTOL applications that prioritise:
- Weight reduction: through aluminium and bimetallic tab options, including our proprietary Flyweight tab
- Thermal stability: with materials and surface treatments suited to high-power applications
- Custom fit: dimensions and layering tailored to specific cell and module requirements
- Manufacturing flexibility: low minimum order quantities and responsive lead times, from our UK facility
Our Flyweight tab, in particular, has already been adopted in weight-sensitive motorsports applications, where every gram counts, replacing most of the copper with aluminium while maintaining performance at both ends of the battery system.
For Programmes That Can’t Afford to Wait
Whether you’re building prototype packs or preparing to scale, our team works directly with engineers to provide fast, relevant input on tab geometry, stacking, and joining methods.
If you’re working on eVTOL cell designs and want pouch cell tabs that are built to perform under pressure, we’d be happy to talk.
