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FPC vs FDC CCS: Which Signal Collection Solution Is Better?

FPC CCS and FDC CCS are two flexible signal collection technologies used in integrated battery cell contact systems. Both are designed to replace traditional wiring harnesses with more compact, integrated solutions that support automated assembly and modern battery module designs.

FPC CCS uses flexible printed circuits produced through chemical etching processes. These circuits provide high wiring density, excellent flexibility, and stable electrical performance. They are widely used in applications requiring lightweight structures and high integration levels.

FDC CCS uses flexible die-cut circuits manufactured through mechanical cutting processes. Compared with FPC, FDC simplifies the production steps and reduces processing time. It is often considered a cost-optimized alternative to FPC in large-scale production projects.

Both technologies integrate signal acquisition directly into the CCS structure, enabling:

• Voltage sampling from each battery cell

• Temperature monitoring through sensors

• Signal transmission to the BMS

• Compact and modular battery layouts

As battery modules become larger and more integrated, flexible CCS technologies such as FPC and FDC are becoming increasingly common in energy storage and electric vehicle applications.

Types of FPC and FDC CCS

FPC and FDC CCS solutions are typically built around similar structural concepts but use different signal circuit technologies.

FPC CCS

Typical structure:

• Flexible printed circuit

• Nickel tabs or conductive pads

• Aluminum busbar

• Insulation layers (PET or PI)

• Heat-pressed or thermoformed support structure

This configuration provides a highly integrated and lightweight signal collection solution.

FDC CCS

Typical structure:

• Die-cut flexible circuit

• Integrated copper traces

• Aluminum busbar

• Simplified insulation structure

In some advanced designs, copper tabs can be extended directly from the circuit to the busbar, eliminating the need for additional nickel tabs.

Features of FPC vs FDC CCS

FPC CCS

FPC-based CCS solutions are widely used in high-performance battery modules due to their excellent electrical and mechanical properties.

Key advantages include:

• Ultra-lightweight structure

• High wiring density for compact modules

• Excellent insulation performance

• Integrated voltage and temperature sensing

• Stable signal transmission

• High compatibility with automated assembly

However, the chemical etching process used in FPC production increases manufacturing complexity and cost.

FDC CCS

FDC-based CCS solutions focus on cost efficiency and production scalability.

Key advantages include:

• Simplified production process compared to FPC

• Mechanical die-cut manufacturing method

• Up to 30% lower process cost

• Shorter production cycle

• Environmentally friendly processing

• Suitable for high-volume production

FDC solutions provide a good balance between performance and cost, especially for large-scale energy storage projects.

Applications of FPC and FDC CCS

Both FPC and FDC CCS technologies are widely used in modern lithium battery systems.

Typical applications include:

• Commercial and industrial energy storage systems

• Containerized ESS platforms

• Grid-scale battery storage

• Electric vehicle battery modules

• High-capacity lithium battery packs

In general:

• FPC CCS is preferred in high-performance or lightweight battery modules.

• FDC CCS is commonly used in cost-sensitive and large-scale production projects.

As energy storage systems grow in capacity, cost-effective solutions like FDC are gaining popularity, especially in utility-scale and industrial applications.

Price of FPC and FDC CCS

The cost of energy storage systems for renewable energy integration depends on several factors, including system capacity, storage duration, battery type, control software, installation conditions, and auxiliary equipment.

Pricing is usually quoted under international trade terms such as EXW, FOB, or CIF, depending on project location and logistics preferences. For a tailored quotation based on your specific project needs, it's best to consult directly with the supplier.

How to Select Between FPC and FDC?

When choosing between FPC and FDC CCS solutions, the decision should be based on project priorities and technical requirements.

Choose FPC CCS when:

• Weight reduction is critical

• High integration is required

• Compact battery module design is needed

• Signal accuracy and performance are top priorities

• Project budget allows for higher material cost

Choose FDC CCS when:

• Large-scale production is planned

• Cost reduction is a key objective

• Manufacturing efficiency is important

• Module structure allows simplified circuits

• The project focuses on long-term cost optimization

In many cases, manufacturers may evaluate both solutions during the design phase to determine the best balance between performance and cost.

The Supplier of FPC and FDC CCS

Integrated CCS solutions based on FPC and FDC technologies are commonly used in modern energy storage battery modules. These solutions are compatible with a wide range of ESS architectures, including air-cooled and liquid-cooled systems for commercial, industrial, and grid-scale applications.

If you are interested in FPC and FDC CCS products or would like to learn more about battery module connection solutions, please contact Dagongess for further information.