A key component of this transition is innovative materials and technologies that reduce the environmental footprint of electric vehicle batteries (EVBs) and improve their performance. This goes far beyond lowering emissions. It’s about rethinking every detail. The ultimate goal is to create batteries that leave a smaller footprint while still delivering the power and reliability we’ve come to expect.

Reimagining sustainability for EVBs

Reducing carbon emissions is necessary and to make a difference we must think bigger and consider every stage of a battery’s life. One of the most important developments in this area is lightweighting. Lightweighting is the process of replacing heavier components with less heavy alternatives to improve energy efficiency. The less an EV weighs, the less energy it needs to move, allowing vehicles to go further on a single charge. This not only boosts performance but makes the entire design more sustainable.

Equally important is end-of-life recycling. As the number of EVs on the road increases, so does the need for better recycling solutions for EVBs. Ensuring batteries can be easily disassembled  for recycling or reuse is crucial. Manufacturers are already looking at ways to give batteries a ‘second life’ or repurpose them for stationary applications, but designing for easier disassembly from the start is essential for minimizing waste.

Enabling sustainable solutions with advanced adhesives

While often overlooked, adhesives play a big role in the sustainability of EVBs. At Avery Dennison, our pressure-sensitive adhesives (PSAs) are helping manufacturers meet sustainability goals, all while maintaining top-tier performance. Here’s how:

• Lightweighting and durability: Our PSAs make it possible to securely bond lighter, polymer-based components, which reduces the overall weight of the vehicle. Not only does this cut down on energy use, but it also allows for more flexible, efficient designs that save on materials.

• End-of-life recyclability: Some adhesives, like thermoplastic PSAs, can debond under specific conditions (such as heat), making it easier to disassemble and recycle EV components at the end of their lifecycle.

• Low environmental impact: Our solvent-free adhesives, like UV-cured acrylics and hot melt rubbers, offer a more sustainable alternative to traditional options. These adhesives provide excellent moisture and chemical resistance without harmful emissions, helping reduce environmental impact right from the start.

In addition to our adhesive solutions, we are committed to providing sustainable facestock and release liner options to further reduce environmental impact. Our durable sustainable facestocks portfolio includes products made with recycled PET (rPET) and recycled polypropylene (rPP), both of which offer performance on par with their virgin material counterparts but with significant CO2 savings. Here is what we can provide in a nutshell:

• rPET facestock (chemical recycling): Made from 70% post-consumer recycled (PCR) material, offering products a chemical recycling source with performance equal to standard polyester films. In addition to being sustainable, these solutions also meet the demanding performance standards required in automotive, electronics, and appliance applications.

• rPET facestock (mechanical recycling): Composed of 30% post-consumer recycled (PCR) material, this facestock is sourced through a mechanical recycling process, such as clean PET bottle collection. These films maintain the same high performance as standard polyester options, meeting the rigorous standards required for use in automotive, electronics and appliances. 

• rPP facestock: This white polypropylene film contains 30% recycled content and reduces environmental impact while maintaining top-tier print performance. It is especially suited for lower-demand applications like short-term identification and warning labels.

• FSC certified glassine release liners: FSC certified liners—available with many of our PSA products—are produced from sustainable sources and are recyclable.

• Recycling of paper and plastic liners: Our AD Circular program, which is available across Europe, collects liner waste from PSA users to be recycled.

By working with us early in the design phase, manufacturers can unlock new possibilities for cutting the environmental impact of EVBs, improving performance, and simplifying the recycling process.

The importance of embracing digital innovation 

Sustainability in EV batteries doesn’t stop at materials. Increasingly, it’s about tracking and managing their lifespan, from sourcing to disposal. A key development here is the Digital Battery Passport (DBP), a regulatory initiative set to launch in the EU by 2027. The DBP will require manufacturers to track the environmental credentials of their batteries digitally—everything from the raw materials used to the carbon footprint of the production process and end-of-life recycling.

This might sound like a challenge, but at Avery Dennison, we’re already ahead of the game. Our digitally enabled labels provide complete traceability, helping you meet regulatory requirements while offering greater transparency. This kind of data ensures compliance and is a powerful way for manufacturers to showcase their commitment to sustainability. And as the push for these solutions grows, this level of transparency will be essential.

What this means for you

So, what does all this mean for technical leaders, R&D teams and procurement managers? A few things stand out:

• Sustainability isn’t a choice anymore—it’s a must: From lightweighting to recyclability, the shift toward greener batteries is happening now, and it’s critical for long-term success.

• Advanced materials are changing the game: Sustainable adhesives like ours are already enabling greener, more efficient EV battery designs that don’t sacrifice performance.

• Digital traceability is the future: With the Digital Battery Passport just around the corner, transparency in the battery life cycle will soon be a regulatory requirement—and those who embrace it early will have a significant edge.

In the end, sustainability isn’t just about ticking boxes or meeting regulations—it’s about rethinking the way we create, use and reuse materials. And in the fast-moving world of electric vehicles, those who adopt these shifts early will be the ones driving the innovation of tomorrow.

If you’d like to learn more about how our adhesive solutions can help you meet your sustainability goals, don’t hesitate to get in touch with your Avery Dennison contact. Or alternatively, visit our website for more information.