The electric vehicle revolution is entering a new phase, and PEEK film (polyetheretherketone film) is at the center of it all. As NEV penetration rates surpass 60% and the industry shifts toward 800V and higher architectures, traditional insulation materials are reaching their limits. PEEK film offers a compelling alternative—delivering superior dielectric strength, thermal stability up to 260°C, and mechanical performance at a fraction of metal's weight. Recent breakthroughs include Hyundai Mobis' development of a PEEK film that boosts EV motor output by approximately 5%, Syensqo's Ajedium™ PEEK slot liners that enhance e-motor efficiency by up to 2%, and successful integration into 800V+ systems by leading powertrain manufacturers. This article examines the material innovations, industry milestones, and market trends driving PEEK film adoption in the global automotive sector.
The first quarter of this year marked a historic milestone—new energy vehicle penetration rates surpassed 60% for the first time, even as overall automotive sales declined by 5%. This tipping point signals an irreversible shift toward electrification. But with this transition comes an urgent challenge: how to make electric vehicles lighter, more efficient, and capable of handling increasingly demanding electrical architectures.
Enter PEEK film (polyetheretherketone film). This high-performance engineering plastic is rapidly becoming the material of choice for automotive engineers tackling the toughest challenges in EV design—from high-voltage motor insulation to battery thermal management and lightweight structural components.
In a landmark development announced in December 2025, Hyundai Mobis successfully created a polyetheretherketone (PEEK) film that increases electric vehicle drive motor output by approximately 5%. This high-performance plastic is lightweight yet heat-resistant, and when wrapped around the copper wires (coils) tightly wound inside electric motors, it blocks abnormal current flow and prevents overheating.
The significance of this breakthrough cannot be overstated. Previously, manufacturers relied on a synthetic fiber called aramid for this application. However, by applying PEEK film, Hyundai Mobis achieved improved coil fill factor and thermal efficiency—directly translating to increased motor output. The surface of this PEEK film is more uniform than existing materials, reducing friction during the coil insertion process and improving overall process efficiency. The company has also ensured durability so that the PEEK film can withstand temperatures above 180°C.
This achievement represents a significant leap forward in EV motor efficiency and demonstrates why PEEK film is rapidly replacing traditional insulation materials in next-generation electric powertrains.
As electric vehicle architectures evolve from 400V to 800V and beyond, insulation materials face unprecedented demands. Higher voltages require superior dielectric strength, thermal management, and long-term reliability under extreme conditions.
PEEK film has emerged as the solution. Syensqo's Ajedium™ PEEK film technology has been successfully tested with 800-volt systems, demonstrating superior copper fill and heat dissipation capabilities compared to traditional aramid paper alternatives. This enables manufacturers to downsize e-motor and battery designs while eliminating the need for conventional moisture management systems.
The technical advantages are compelling. PEEK slot liners provide enhanced dimensional stability and reduced thermal expansion coefficients compared to traditional polyimide films, enabling tighter manufacturing tolerances and improved electromagnetic performance. The reduced insulation thickness achieved through PEEK film implementation directly impacts motor power density metrics—by increasing the copper fill factor within existing slot constraints, engineers can achieve higher current density while maintaining acceptable I²R losses.
In high-performance applications where peak power requirements exceed 300 kW, these improvements are critical. Thermal management improvements stem from PEEK film's superior heat transfer characteristics compared to air gaps typically found with thicker insulation systems, reducing hot spot formation and enabling higher continuous power ratings.
The transformative potential of PEEK film has not gone unnoticed by the automotive industry. Syensqo's Ajedium™ PEEK drive motor insulation slot liner was named a finalist for the 2025 Automotive News PACE PILOT Innovation Forward Award.
Brian Baleno, Director of Global Business Development and Program Management at Syensqo, emphasized: "Our polyetheretherketone (PEEK) film has been successfully tested with 800-volt systems, demonstrating superior copper fill and heat dissipation capabilities compared to traditional aramid paper alternatives".
This recognition underscores the industry's growing consensus that PEEK film is not just an incremental improvement but a transformative material enabling the next generation of electric vehicles.
The momentum behind PEEK film is further evidenced by strategic industry partnerships. Syensqo and Politubes announced a partnership to develop slot liner spiral-wound tubes using Ajedium™ PEEK and polyphenylsulfone (PPSU) film. These spiral-wound slot liner tubes leverage the high-performance properties of Ajedium™ PEEK films, providing superior insulation for electric motors.
The unique product design enhances e-motor efficiency by up to 2%, enabling a more effective copper fill factor and improved heat dissipation. This allows manufacturers to benefit from lightweighting and reduced total costs while gaining higher efficiency and increased packaging space within vehicles.
Federico Penzo, CEO of Politubes, noted: "Over the past years, we've seen increasing demand from automotive original equipment manufacturers for EVTubes made with PEEK or PPSU".
The comparison between PEEK film and traditional aramid paper is striking. Research has demonstrated that PEEK-based nanocomposite paper achieves a breakdown strength of 89.67 kV/mm—representing a 256% improvement over commercial aramid paper. After thermal aging at 200°C, the performance gap becomes even more pronounced.
Ajedium™ PEEK slot liners provide enhanced dimensional stability and reduced thermal expansion coefficients compared to traditional polyimide films. This enables tighter manufacturing tolerances and improved electromagnetic performance—critical factors in high-performance EV motors.
With density仅为金属的几分之一 (仅为金属密度的几分之一), PEEK film delivers dramatic weight reduction without sacrificing mechanical integrity. The material's tensile strength and thermal stability make it a viable replacement for metals in applications ranging from motor components to battery insulation.
PEEK film is revolutionizing motor insulation. Ajedium™ PEEK slot liners and slot wedges, alongside KetaSpire® PEEK magnet wire insulation, address critical design challenges in high-performance traction motors. The monolayer KetaSpire® PEEK magnet wire insulation system offers:
PEEK film serves as an insulation layer for electric vehicle batteries, providing exceptional high-temperature resistance, mechanical strength, and chemical resistance. The material's ability to withstand prolonged exposure to high temperatures and mechanical stresses makes it ideal for demanding battery applications.
With continuous operating temperatures up to 260°C, PEEK film is ideal for engine compartment and under-hood applications where traditional polymers would fail. The material maintains stable performance in high-temperature, high-pressure environments.
PEEK film provides high-performance insulation for wire, cable, and protective sheaths, offering exceptional durability and lightweight properties.
The global polyetheretherketone (PEEK) film market is experiencing robust growth. According to QYResearch, the market reached approximately $179 million in 2025 and is projected to reach $271 million by 2032, growing at a compound annual growth rate (CAGR) of 6.2%.
Several factors are driving this growth:
As system voltages continue to increase toward 1000V and beyond, PEEK film innovations in insulation technology will become increasingly critical for achieving target power density and efficiency metrics.
Beyond performance, PEEK film contributes to sustainability goals. The material enables:
As major countries legislate the use of eco-friendly materials—the European Union has mandated that, starting in 2030, 25% of plastics used in new vehicles must be recycled plastics—PEEK film's durability and recyclability become increasingly valuable.
The electric vehicle industry is at a pivotal moment. NEV penetration has crossed the 60% threshold, 800V architectures are becoming standard, and performance demands continue to escalate. PEEK film (polyetheretherketone film) stands uniquely positioned to meet these challenges.
From Hyundai Mobis' breakthrough PEEK film that boosts motor output by 5% to Syensqo's award-winning Ajedium™ PEEK slot liners that enhance e-motor efficiency by 2%, the evidence is clear: PEEK film is not just an alternative—it is the superior choice for next-generation electric vehicles.
With its exceptional lightweighting capabilities, high-temperature resistance up to 260°C, superior dielectric strength, and proven performance in 800V systems, PEEK film enables engineers to design vehicles that are lighter, more efficient, and more reliable than ever before.
The future of automotive lightweighting and electrification is here—and it's made of PEEK.
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