Charged EVs | Customized EV connectors: ENNOVI’s approach to automotive interconnects

In the rapidly evolving automotive landscape, electrification is reshaping the industry, driving companies like ENNOVI to innovate specialized solutions. Charged recently chatted with ENNOVI’s team—CEO Stefan Rustler, Managing Director Michael Meckl and Product Manager Till Wagner—to learn more about its approach to automotive interconnects.

Founded just over a year ago, yet built on a foundation of 60 years of automotive manufacturing expertise, ENNOVI emphasizes five strategic pillars: speed, innovation, talent, global outreach, and sustainability. These pillars position the company as a significant player in electric vehicle technologies, particularly within battery interconnect, power solutions, and signal interconnect applications.

ENNOVI’s strength lies in its capacity to customize interconnect solutions tailored specifically to customer requirements. Early engagement and collaborative approaches ensure their global teams effectively anticipate and fulfill client needs. Through regional teams, competence centers, and extensive factory networks—comprising 14 facilities and four innovation hubs globally—ENNOVI guarantees a smooth transition from concept to production, helping clients rapidly scale solutions.

A vital component of ENNOVI’s strategy is sustainability, integral to both its operational practices and product design. Achieving five consecutive EcoVadis Platinum awards underscores ENNOVI’s long-term commitment to environmental responsibility. This commitment encompasses reducing material and electricity consumption, implementing recyclable packaging solutions, and establishing closed-loop water systems within their manufacturing processes.

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Innovative battery module design remains critical to the EV industry’s evolution. ENNOVI specializes in manufacturing battery module components, such as advanced cell contacting systems. Aware of ongoing challenges such as varying cell form factors and chemistries, ENNOVI has developed adaptable manufacturing technologies, including stamping, molding, lamination, and laser welding. These solutions offer flexibility in meeting dynamic market demands and enable more efficient production processes.

One specific innovation highlighted by ENNOVI is the advancement of adhesive-free lamination technology for cell contacting systems. Traditional plastic trays, heavy and space-consuming, reduce overall battery energy density. ENNOVI’s adhesive-free lamination approach eliminates environmental impacts associated with adhesives while improving cycle times, demonstrating significant advancements in both ecological efficiency and performance optimization.

Additionally, ENNOVI is responding effectively to the increased demand for higher voltage and faster charging capabilities in EV power systems. With typical EV voltages rising from 400–500 volts up to 800–1000 volts, ENNOVI addresses these challenges by innovating more compact and cost-effective bus bar connections. Their new sealing technologies shorten production cycles, reduce costs, and expedite market entry, reinforcing ENNOVI’s role in accelerating the automotive industry’s electrification journey.