​Custom Automotive FPC Flexible Circuit Board for Lithium Battery CCS & ADC Sampling

Reliable Battery Interconnect Solutions for Automotive & Heavy-Duty EV Modules
​As the global transition to electric mobility accelerates, precise battery management and high-reliability interconnections have become paramount. Our premium FPC flexible printed circuit boards are engineered specifically for Cell Contact Systems (CCS) in lithium-ion battery packs. Designed to replace traditional wire harnesses, these flexible sensing assemblies streamline ADC voltage sampling and temperature monitoring for electric buses, commercial EVs, energy storage systems (ESS), and automotive battery modules.
​Technical Specifications & Capabilities

Technical Parameter                  Specification Range / Standard
Base Material                             Polyimide (PI) / Polyester (PET) Flame Retardant
Copper Thickness                      0.5 oz to 3 oz (Heavy Copper Available)
Layer Count                               Single-sided, Double-sided, Multi-layer FPC
Voltage & Current Sensing         Integrated Nickel/Aluminum Busbars & ADC Contacts
Temperature Sensor Integration NTC Thermistors (Solder/Surface Mount)
Operating Temperature              -40°C to +125°C
Flame Retardancy                      UL94-V0 Standard
Insulation & Dielectric                 High Dielectric Strength Polyimide Coverlay
Certifications                               IATF 16949, ISO 9001, RoHS, REACH Compliant

Why Upgrade to FPC-Based CCS Battery Sensing Assemblies?
​Traditional wired harnesses increase module weight, manual assembly errors, and thermal bottleneck risks. Our automotive-grade FPC wiring harnesses offer superior physical and electrical efficiency for lithium battery pack assembly:
​1. High-Density Integration & Space Efficiency
​Integrated FPC flexible circuits consolidate multiple ADC sampling lines, NTC temperature sensors, and signal lines into an ultra-thin, flat profile. This compact layout maximizes volumetric energy density in EV bus battery packs and large-scale ESS enclosures.
​2. High Precision ADC Sampling & Thermal Safety
​Precise voltage sampling and accurate temperature detection are vital for battery management systems (BMS). Our continuous automated production guarantees accurate resistance tolerances, minimizing measurement drifts across all ADC sampling points.
​3. Automated Assembly & Cost Reduction
​Equipped with positioning holes and standardized terminal interfaces, our CCS FPC harnesses support automated pick-and-place assembly. This substantially cuts down manual wiring labor costs and reduces risk of human assembly error.
​4. Vibration Resistance & Automotive Reliability
​Built to withstand harsh commercial vehicle environments, our FPC harnesses undergo rigorous vibration, thermal shock, and high-humidity testing, meeting stringent automotive automotive standards (IATF 16949).
​Application Scenarios
​Our custom CCS battery FPC assemblies are optimized for diverse high-voltage energy storage applications:
​Electric Buses & Commercial Fleets: High-durability signal lines built for high-capacity heavy-duty battery packs.
​Passenger EVs & Plug-in Hybrids: Compact battery busbar FPCs tailored for tight OEM module footprints.
​Energy Storage Systems (ESS): Scalable FPC solutions for commercial and utility-grade lithium battery racks.
​Custom Battery Pack OEMs: B2B turn-key designs integrating custom stiffeners, connectors, and busbar welding interfaces.
​OEM / ODM Customization Workflow for Global Buyers
​We provide end-to-end custom engineering for EV battery manufacturers and Tier-1 automotive suppliers:
​Design & Schematic Evaluation: Gerber/CAD file review and signal trace optimization.
​Material Selection & DFM Analysis: Customizing copper weights, PI insulation layers, and stiffeners.
​Prototyping & Functional Testing: Rapid prototype delivery with full electrical, thermal, and dimensional inspection reports.
​Mass Production & SMT Assembly: Automated SMT mounting for NTC thermistors and connectors, followed by 100% AOI and E-test verification.
​Partner with a Trusted Automotive FPC Harness Manufacturer
​Get high-precision CCS battery FPCs tailored to your technical specifications. Contact our engineering team today for technical drawings, custom DFM feedback, or wholesale RFQ quotes

Source manufacturer, safety and quality let you rest assured

Focusing on FPC for more than ten years, Androw Technology looks forward to cooperating with you. Work together to create high-quality,high-end products