Li-ion Batteries (LIB)
Aluminium Laminated Film
Lithium ion cell manufacturers use laminated aluminium film to form the packaging for their pouch cells. This is a material made up of aluminium foil sandwiched between multiple layers of polymers such as PET, PA and CPP.
Avocet Precision Metals offer lithium ion cell manufacturers multiple thickness and material combinations so that our customers can maximise their cell output. Utilising our partnership with one of the worlds best manufacturers of laminated aluminium, Avocet are in a fantastic position to provide our clients with the technical expertise and product quality required by Lithium ion battery manufacturers.
Working in partnership with our clients means that we understand the demands and challenges faced by manufacturers. Avocet Precision Metals supply both small volumes for start up and research companies, tailoring their specification to meet their exact needs, as well as supplying high volumes for mass production. We are very well positioned in the market to help our clients develop their new battery technologies, as well as improving already existing designs.
The trend for battery technologies is to produce higher power whilst reducing weight and dimensions. Our laminated foils, supplied in rolls up to 520mm wide can be supplied in thick dimensions to be used in larger batteries such as for EV applications, but also very thin dimensions to be used in consumer electronic applications where reduced weight and dimensions are so important.
Laminated Aluminium Foil For Pouch Cells – Thickness Guide & Datasheets.
Please find below a list of our standard thickness’s, all available as downloadable datasheets.
Avocet Precision Metals willingness and ability to supply small quantities of bespoke manufactured laminate foils for test and evaluation is proving to be a key resource for the new and expanding European manufacturing sector of Lithium ion batteries.
This facility can of course be quickly followed by pre-production and full production volumes at a competitive price once homologation is achieved.
Please use the contact us page or send an enquiry to sales@avocetsteel.co.uk and a member of our team will be in touch.
High-Performance Pouch Film for Solid-State Battery Applications
As solid-state battery (SSB) technology accelerates toward commercialisation, the demands on packaging materials are growing more extreme. Manufacturers require solutions that can endure high temperatures, withstand ultra-high pressures, and maintain barrier integrity under aggressive processing conditions.
Our high-performance safety pouch film has been specifically developed for these challenges, offering mechanical strength, thermal stability, and chemical resistance suitable for next-generation SSB designs.
Safety Pouch Film: Built for Extreme Heat and Pressure
Performance in Warm Isostatic Press (WIP) Conditions
Solid-state battery cells are often manufactured using Warm Isostatic Pressing (WIP), subjecting the pouch to intense conditions, often above 100°C and 4,000 bar. This pouch film is engineered to survive and perform in that environment, reducing porosity and maintaining seal strength throughout the process.
Qualified by major OEMs, this film supports solid-state battery applications where conventional pouch materials fall short.
Key features
- High rupture strength at room and elevated temperatures
- Thermal durability under WIP conditions up to 120°C
- Electrolyte resistance over extended exposure (Day 1 & Day 7 tested)
- Low porosity and deformation post-WIP processing
- Compatible with solid-state and hybrid lithium chemistries
Technical Highlights – Pouch Film for WIP
| Item | Al Pouch Film for WIP | Measuring Methods |
|---|---|---|
| Outer Layer Seal Strength - RT | Rupture | UTM @ 25°C |
| Outer Layer Seal Strength - 120°C | Rupture | UTM @ 120°C |
| Formability (mm) | 17.0 | Forming Machine |
| Inner Layer Seal Strength - RT | 16.4 | TA @ 25°C |
| Inner Layer Seal Strength - 120°C | 6.8 | UTM @ 120°C |
| Inner Layer Seal Strength - Electrolyte Resistance (Day 1) | 19.2 | TA after dipping in EL 1 & 7 Days @ 25°C |
| Inner Layer Seal Strength - Electrolyte Resistance (Day 7) | 19.5 | TA after dipping in EL 1 & 7 Days @ 25°C |
| Seal Strength (N/15mm) | 158.8 | UTM @ Pouch/Pouch |
| Puncture Strength (N) | 35.5 | ASTM D 6241 |
All tests performed under controlled laboratory conditions. Detailed technical data available upon request.
Applications
- Solid-state pouch cells
- Warm Isostatic Press (WIP) packaging
- EV battery modules using SSB chemistry
- Industrial energy storage systems requiring ultra-high mechanical stability
Available Options
- Standard and custom thicknesses available
- Slit rolls or cut-to-size formats
- Technical data sheets, forming trials, and sample rolls available on request
- Cleanroom-compatible packaging upon request
Please use the contact us page to make any enquiry and our sales team will be in touch.
Aluminium Laminated Film FAQs
What is aluminium laminated film?
Aluminium laminated film is a multi-layer packaging material used to manufacture lithium-ion pouch cells. It combines an aluminium foil core with specialised polymer layers to create a lightweight, flexible and highly protective battery enclosure. The film provides the barrier properties needed to protect sensitive battery materials from moisture, oxygen and electrolyte leakage while allowing the cell to be formed into complex shapes.
What is aluminium laminated film used for in lithium-ion batteries?
Aluminium laminated film forms the outer pouch of a lithium-ion battery. It safely contains the electrodes, separator and electrolyte while protecting the cell from environmental contamination. Its combination of strength, flexibility and barrier performance makes it the preferred packaging solution for modern pouch cell designs used in EVs, energy storage systems and consumer electronics.
What layers make up aluminium laminated film?
Aluminium laminated film typically consists of three functional layers: an outer polyester (PET) or nylon (PA) layer for mechanical strength, a central aluminium foil layer for moisture and gas protection, and an inner polypropylene (PP) layer that seals directly to the battery pouch. Each layer performs a specific role to maximise battery safety and performance.
Why is aluminium laminated film used in pouch cells?
Pouch cells require packaging that is lightweight, formable and highly protective. Aluminium laminated film provides excellent barrier properties while reducing overall battery weight compared with rigid metal housings. This allows manufacturers to maximise energy density and create thinner, lighter battery packs for demanding applications such as electric vehicles and aerospace systems.
What thickness of aluminium laminated film is used for lithium-ion batteries?
The most common pouch films range from approximately 68μm to 156μm, although the ideal thickness depends on cell size, cavity depth and application requirements. Thinner films are often used for lightweight consumer devices, while thicker constructions provide additional strength and durability for larger EV and energy storage batteries.
Is aluminium laminated film suitable for solid-state batteries?
Yes. Advanced laminated pouch films are increasingly used in solid-state battery development because they offer excellent mechanical strength, heat resistance and sealing performance. Selecting the correct film structure is especially important in solid-state applications, where operating conditions and forming requirements can be more demanding than conventional lithium-ion cells.
What barrier properties does aluminium laminated film provide?
The aluminium core acts as an extremely effective barrier against moisture, oxygen and other contaminants that can damage battery chemistry. Combined with specialised polymer layers, the film also provides puncture resistance, electrolyte resistance and durable heat-seal performance, helping improve battery safety, reliability and service life.
Can aluminium laminated film be supplied in rolls or preformed pouches?
Yes. Aluminium laminated film can be supplied as slit rolls for high-volume manufacturing or as preformed pouches to reduce processing steps and improve production efficiency. The best option depends on the battery design, manufacturing process and production volume.
What are the benefits of pouch cell packaging?
Pouch cells offer an excellent combination of low weight, high energy density and design flexibility. Unlike rigid cylindrical or prismatic casings, pouch packaging can maximise the use of available space, making it an attractive solution for electric vehicles, aerospace systems, portable electronics and next-generation battery technologies.
What polymers are used in aluminium laminated film?
The most commonly used polymers are PET (polyethylene terephthalate), PA (polyamide/nylon) and PP (polypropylene). Together these materials provide mechanical strength, flexibility, chemical resistance and reliable heat sealing, which are all essential for safe battery operation.
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We are proud to have been awarded ISO 9001 certification, an internationally recognised standard that ensures services meet the needs of clients through an effective quality management system. Our decision to work towards ISO 9001 certification demonstrates our commitment to providing a high-quality and consistent service to our clients and our ongoing investment in technology, development and processes and procedures.
You can download a copy of our ISO 9001 : 2015 certificate here.
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