Electrification, sensors, infotainment, interior, and exterior lighting, and the potential for autonomous functionality are transforming the automotive vehicle into a sophisticated electronic device on wheels. This increased electronic content demands a circuit technology that can be folded, fit into small spaces, provide unique functionality, and 3D structures allowing for space and weight savings. 
Sheldahl has been providing Flexible Circuits to the automotive industry for almost 60 years. Sheldahl provided the first Flexible Circuit into the ‘65 Ford Thunderbird and from those early instrument clusters to today’s sensor, heaters, and lighting applications, demonstrating a history of circuits that have been driven billions of vehicle miles in the harshest of environments.

Battery Management
Sheldahl Bus Bond material
Bus Bar Materials use in Electric Vehicles

With the electrification of the automobile industry, the monitoring of the battery's state and health is critical. This requires a flexible and intelligent harness to interconnect to the individual cells, capable of adapting to the expansion and contraction of the battery pack during charge/discharge cycles.

Flexible Printed Circuits can effectively link the cells to the vehicle's electronics. The necessary electronic components can be surface mounted to the FPC, while the inherent flexibility allows for the battery pack's expansion/contraction. These flexible technologies can deliver a smaller and lower weight solution that will enable better MPC (Miles per Charge).

In addition to the monitoring of battery cells, we have been developing and designing heaters for batteries. These thin-film applications can be sandwiched between the individual cells to significantly reduce charging time and extend the overall lifetime of the battery in cold climate conditions.

Our vertical integration provides the broadest range of material, fabrication, and assembly capabilities in the industry. We excel in the collaborative development of new technologies. Our technically experienced staff can help you optimize battery management interconnect and be a partner in developing customized solutions for an evolving, environmentally clean market.


Engine & Powertrain
Automotive Engine and Powertrain
Automotive engine control units (ECU) and transmission controls (TCU)

Due to the demand for higher efficiency in combustion engines and the evolution of electric vehicles, the vehicle engine and powertrain components benefit from flexibility, space savings, weight reduction, reliability in harsh environments, and automatable assembly.

Sheldahl has a long history of making under hood automotive flexible circuit applications. Our experience in these applications and our ability to develop custom materials is unrivaled. For example, our Novacladâ material has proven to be extremely reliable in tens of millions of vehicles for harsh environment applications like engine control units (ECU) and transmission controls (TCU).

Flat Flex Cable (FFC) Insulation Material
Flat Flex Cable Tape Materials
Vehicle steering column Flat Flex Cable Tape

As the automotive industry moves toward creating safer vehicles developing a better connection between the driver and the vehicle is paramount. The steering wheel becomes the key connection point for interfacing effectively, integrating humans and computers, working together for a safer and more comfortable driving experience.
Flat Flex Cable (FFC) Insulation Materials provide the ideal connection technology for curved, tight spaces and flat surfaces, capable of repeatedly turning back on itself for years of use.

Sheldahl produces various FFC products for clock springs, wiring for automotive headliners, jumpers/interconnections, and more. If you need a secure and durable connection, we work in prototype development and large-scale production. Sheldahl has the experience, knowledge, and technology to support the most difficult projects customizing our FFCs to meet your needs.

Fuel Cell Materials
Fuel Cell Materials for new Hydrogen powered vehicles

The world is changing to create an eco-friendly future where fossil fuel vehicles are no longer the standard but are replaced with cleaner modes of transportation. Using the chemical energy of hydrogen, Fuel Cells cleanly and efficiently produce electricity and as electric powered vehicles become the new standard for transportation, the need for the technology to support increases.

Our adhesive coated PEN (Polyethylene Naphthalate) materials have been a critical enabler over the last 20 years.

Our vertical integration provides the broadest range of material, fabrication, and assembly capabilities in the industry. We excel in the collaborative development of new technologies. Our technically experienced staff can help you optimize your Fuel Cell development and be a partner in creating customized solutions for an evolving, environmentally clean market.

Copper based Flexible Circuit Automotive seat heaters
copper based flexible circuit heater
Vehicle seat heating circuit
Heating circuit with components

As the automotive industry moves away from traditional combustion engines to electric vehicles, the delivery of comfort to the occupants and controlling battery temperature is proving to be a challenge.
Flexible Circuits can provide localized heating to the battery, seats, floor mats, and steering wheels, improving the MPC (Miles Per Charge). Flexible printed heaters deliver directed heat more efficiently than traditional air circulation systems.

We are currently working with major automotive Tier 1 suppliers and OEMs (Original Equipment Manufacturers​​​​​​) to develop new heating and cooling solutions that adjust to tight spaces, curved or flat surfaces, providing lower weight options. Our material and circuit knowledge allow us to aid in the design of cost-effective solutions that best fit the requirements for various applications.
Human Machine Interface
Human Machine Interface
Human Machine Interface Automotive Center Console
Touch Sensor flexible circuitry
Autonomous vehicles touch sensor solution
vehicle human machine interface overhead console
Human machine interface printed circuit heads up display
Automotive Center Console Human Machine Interface Flexible Circuit

The Automotive interior has transitioned to essentially become a sophisticated computer on wheels. The desire to improve the customer experience has led Automotive OEMs to replace electromechanical switches with touch sensor technology.

As OEMs and Tier 1 suppliers work to transition mechanical buttons and switches to touch sensors, flex circuits can play a key role. They can be integrated into tight, curved, or flat surfaces, converting plastic surfaces into smart surfaces. Flex circuits can meet these challenges while reducing assembly and bill of material costs.

Sheldahl Flexible Technologies offer the broadest range (PEDOT, ITO (Indium Tin Oxide), Nano Silvers, Silver, Carbon, Etched Copper) of flexible and dependable touch sensor solutions to address multiple applications within the automotive vehicle. We are an innovator in transparent capacitive touch, including haptic feedback. As a part of our continuous improvement effort to meet market demands, we are always developing new technological capabilities.
LED Lighting
Automotive LED Lighting
LED head lighting
Automotive LED Lighting
Automotive interior led lighting

Interior and exterior lighting is a key differentiator in automotive design. Flexible Printed Circuits provide unique solutions by delivering 3-D interconnect technology with enhanced thermal performance. The flexibility of the substrate offers fewer interconnects, lighter and smaller packaging, and system savings.

Sheldahl was one of the original providers of LED (Light-Emitting Diode) tail lamps, and then daytime running lights. Our thermal and materials expertise enables us to co-develop the ideal combination of packaging and thermal performance, addressing CTE (Coefficient of Thermal Expansion) mismatch in high-power LED applications.
Seat Sensors
Car seat sensor
Car seat sensor manufacturer

The next generation of drivers requires passive seat sensors to provide proximity, approximated weight, and human presence. In addition, as the Automotive industry shifts to be autonomous, the vehicles evolve from passive to more active, determining the occupants' health and well-being.

Flexible Printed Circuits provide the ideal sensor technology for occupancy and biometric sensing. Our biometric sensing experience in the Health industry is an enabler for future requirements in Automotive seating. As an industry leader commented, the vehicle seat is the ideal wearable device, and flexible circuit technology is the ideal solution for curved, tight spaces and flat surfaces.

Sheldahl is a leader in passive seat sensor technology for the Automotive market. We work with key suppliers to this industry to develop technologies capable of measuring occupancy and managing the higher-level requirements defined by the OCS (Occupant Classification System).




Sheldahl Aerospace Technologies

Sheldahl Aerospace Technologies has supported the space industry since 1958. Our space heritage is unsurpassed in the industry providing thin film material to space missions worldwide.


Electrification, sensors, infotainment, interior and exterior lighting and the potential for autonomous functionality are transforming the automotive vehicle into a sophisticated electronic device on wheels.

Health Solutions

The evolution of the health care industry has led to increased home care, and shortened hospital stays, transforming the medical sector globally. This has led to vital innovation in drug delivery devices, medical devices, remote monitors, sensors, and wireless connectivity. Flexible Circuits & Printed Electronics are critical to the health care industry, providing flexible, adaptable, and clean solutions.
Bridge Lighting

Additional Markets

LED applications are expanding at a rapid pace and are increasingly being used in our daily lives. LED's offer flexibility to adjust spectrums of light to accelerate plant growth or highlight the beauty of your architectural design all while utilizing energy more efficiently. The use of flexible circuits in LED lighting applications can enable 3D packaging, reduce cost, and improve overall lighting performance.

Industrial Abrasive Materials

Let Sheldahl's Industrial Abrasive Material products offer you the advantage of our experience and capabilities.