The Complete Guide to Dielectric Coating Testing for EV Battery Assemblies.
When you are working on critical components like EV battery assemblies, validating your dielectric coating system before full-scale production isn’t just smart but essential. And that’s where aluminium coupon testing comes in, giving you a reliable way to evaluate your dielectric coating performance before undertaking full production.
What is dielectric coupon testing?
Dielectric coupon testing is a low-risk testing process for validating dielectric coating on aluminium components. This early-stage testing can save you time, cost and provide early validation of your dielectric coating system.
At Powdertech, dielectric coatings are applied as per your spec to small aluminium samples, known as “coupons.”
Instead of coating a high volume of full-sized components straight away (which can be expensive and time-consuming), these aluminium test coupons would let us simulate how your dielectric coating will perform under real-world conditions, before coating at scale.
Aluminium coupon testing for dielectric coating at Powdertech’s on-site lab.
Why does early dielectric testing matter?
Many of our automotive clients, particularly in the EV sector, rely on dielectric coatings to provide electrical insulation. However, even with the best coating application, coating systems can behave unpredictably when applied to complex geometries or challenging areas like sharp or rough edges, which can eventually affect insulation.
Through coupon testing facility, we can test for these coating issues early on, giving you insights into:
Coating thickness and dielectric strength
Edge coverage and uniformity
Porosity control and more
Early-stage validation of dielectric coating through aluminium coupon testing, we can rectify these coating issues to make informed decisions early on, before moving to volume coating, reducing the chance of costly failures down the line.
In addition to coupon testing, for high-volume dielectric coating projects, we have a dedicated dielectric test cell and full in-house testing facilities, including:
Hi-Pot and Holiday testing
Isolation resistance measurement and more to validate coating performance with faster turnarounds and reliable testing data that you can act on.
Aluminium coupon testing facility for dielectric coating at Powdertech Surface Science, Bicester, UK.
Partner with Powdertech
Over the years, we have supported major UK OEMs and Tier 1 suppliers with their dielectric coating projects for EVs, helping them optimise their coatings through upfront dielectric testing.
If you are developing a component that requires reliable dielectric insulation, don’t wait for issues to surface during production. Talk to us about aluminium coupon testing to validate your coating early on.
Contact our team to see how Powdertech can support your dielectric coating project.