New water-based coating tech could cut extra steps in EV battery part manufacturing

A new aluminum coating could simplify how battery components are manufactured by protecting the metal during forming while adding properties needed inside electric vehicle and energy storage systems.

Novelis is expanding its portfolio of coated aluminum solutions for battery applications, targeting components including battery enclosures, casings and electrical connectors known as bus bars.

The approach combines automotive-grade aluminum sheet with surface treatments designed to improve corrosion resistance and formability. The company says the coated material can also be engineered to provide electrical insulation for specific battery applications.

A key part of the technology is a water-based coating applied to aluminum coils before they are formed into components. The coating is designed to remain effective after stamping, potentially allowing manufacturers to remove some processing steps used with untreated aluminum.

Coating simplifies battery production

Battery components must withstand demanding manufacturing and operating conditions. Aluminum is attractive because it is lightweight, durable and recyclable, but components may require additional surface treatments to protect them from corrosion or provide electrical insulation.

Novelis says its pre-applied coating can address some of those requirements before the aluminum reaches the forming stage. Because the coating is already on the coil, manufacturers may be able to reduce reliance on external lubrication and additional e-coating processes.

“Leveraging decades of automotive expertise, we have developed aluminum solutions that combine advanced surface technologies with high-performance sheet products for demanding battery applications,” says Milan Felberbaum, Director R&D, Novelis Europe. “By integrating these capabilities, we help customers improve manufacturing efficiency while supporting battery performance and durability.”

The company says the coating has already been proven and is in use on its advanced coating line in Germany. Its ability to withstand stamping is important because battery components often need to be shaped into complex forms after the coating is applied.

Aluminum targets tougher battery demands

The coated aluminum can be used for battery enclosures and casings, where corrosion protection can help improve component durability. It can also be tailored for electrical insulation, a property that can be useful for components that need to prevent unwanted electrical contact.

The technology is aimed at both electric mobility and stationary energy storage. That gives the material a role across different battery systems rather than limiting it to automotive applications.

Novelis is also emphasizing the use of recycled aluminum. The company says high-recycled-content, low-carbon aluminum can support efforts to reduce the environmental impact of battery supply chains. Closed-loop recycling could allow aluminum recovered from products to be returned to the manufacturing cycle.

The announcement is therefore focused less on changing battery chemistry and more on changing the material and manufacturing process around the battery. By combining aluminum’s low weight with a pre-applied coating, the company is targeting a way to make battery components easier to manufacture while meeting durability and insulation requirements.

Fewer steps for battery makers

The approach could also help manufacturers reduce manufacturing complexity if fewer coating and lubrication stages are required. However, the announcement does not provide quantified figures for cost savings, production-time reductions or improvements in battery performance.

Novelis is positioning the expanded portfolio for the growing battery and energy storage markets, building on its experience supplying aluminum products to the automotive industry.