In the race toward safer, more sustainable electric vehicles (EVs), materials innovation is as important as advances in batteries or autonomous driving. One area gaining significant attention is EV adhesives/structural adhesives—specifically, adhesives that can help vehicles withstand high-impact collisions without sacrificing sustainability or safety. Crash-resistant adhesives are able to streamline assembly and provide peace of mind.
Enter Plexus® MA7020 — a next-generation, non-flammable acrylic-based structural adhesive from ITW Performance Polymers, designed to redefine crash resistance in EV manufacturing. With its exceptional performance in impact resistance, fatigue resistance, and thermal safety, Plexus MA7020 is uniquely positioned to meet the demands of modern EV design. Structural bonding for EVs involves lightweight material bonding without compromising on electric vehicle structural integrity.
The Challenge: Bonding for EV Safety, Sustainability, and Performance in One Package
For EV manufacturers, safety and sustainability are non-negotiable. The shift away from traditional internal combustion engines to high-voltage electric platforms introduces new safety challenges—particularly in crash scenarios where battery protection is paramount.
Battery enclosures, body panels, and structural frames must endure high-energy impacts without catastrophic failure. The automotive safety adhesives that bond these components need to be just as tough—while also meeting sustainability standards, such as low VOCs and non-flammability in uncured states.
Why Plexus MA7020 Stands Out
Plexus MA7020 addresses these challenges head-on:
- Non-Flammable Formulation
With a flash point greater than 200°F (93.3°C), Plexus MA7020 is classified as non-flammable in its uncured state. This makes it a safer choice for manufacturing and handling—an important consideration for both production line safety and regulatory compliance. - Exceptional Impact Resistance
In demanding crash simulations, impact wedge peel strength is a critical measure of adhesive toughness. Plexus MA7020 delivers an impressive 24 N/mm impact wedge peel performance—helping structures maintain integrity under sudden, high-stress loads. Crash safety materials rely on high-performance adhesives like Plexus MA7020. - Superior Fatigue Resistance
Vehicle structures experience repeated stresses over their lifetime—from vibrations, thermal cycling, and road impacts. Plexus MA7020’s elongation at break of 70–110% and robust tensile strength (1,475–1,803 psi) mean it can absorb and dissipate these forces without degradation, extending component life. - Bonding Versatility
Designed for metals, composites, and E-coated surfaces, Plexus MA7020 creates strong, durable bonds across a variety of substrates used in EV battery enclosures, crash structures, and body frames. It even incorporates inert glass beads for consistent bond line thickness.
Enabling Crash-Resistant EV Design
Crashworthiness in EVs often hinges on the battery enclosure’s ability to withstand intrusion. Plexus MA7020’s high lap shear strength—up to 1,969 psi on Galvanized steel—and outstanding cohesive failure profile mean the adhesive holds even under destructive forces.
When compared to mechanical fastening alone, structural adhesives like Plexus MA7020 help distribute stresses evenly, reducing localized weaknesses and improving overall structural resilience. This not only enhances safety during a crash but also reduces weight—a key factor in extending EV range.
Sustainability Without Compromise
Sustainability is no longer a secondary consideration, it’s integral to product design. Plexus MA7020’s <1% VOC emissions during cure, minimizes environmental impact, and its non-flammable classification reduces handling issues during application, storage and transportation risks.
Incorporating adhesives like Plexus MA7020 into EV manufacturing supports automakers’ goals of reducing hazardous materials in their production processes without compromising safety or durability.
Applications Across the EV Platform
Plexus MA7020 is suited for:
- Battery pack assembly – bonding structural frames and covers.
- Crash structures – reinforcing side impact beams, pillars, and cross members.
- Lightweight panels – bonding aluminum, stainless steel, and composite panels without mechanical fasteners.
Its reliable performance across temperature extremes and its ability to retain high strength make it a versatile choice for multiple points in EV assembly.
The Road Ahead
As EV adoption accelerates, the industry’s material choices will play a decisive role in shaping vehicle safety and performance. Plexus MA7020 represents a leap forward increasing design freedom; combining non-flammability, superior crash resistance, and long-term fatigue durability in one adhesive solution.
By delivering a 24 N/mm impact wedge peel strength, bonding versatility, and a safer, more sustainable formulation, Plexus MA7020 empowers manufacturers to build EVs that are not just greener—but tougher and safer in real-world driving conditions.
For engineers and designers focused on the next generation of electric vehicles, Plexus MA7020 isn’t just an adhesive—it’s a structural safety enabler.
By: Chintan Patel, Product Marketing Manager
View all our Technical Data Sheets and Safety Data Sheets. Need some help? Ask a technical question and find a solution!
Further reading: Thixotropy, Viscosity and Rheology … Oh my!, What is fixture time anyway?, and Is it strong enough?.
For more information like this, follow ITW Performance Polymers on LinkedIn and sign up for enewsletter in our website footer.
ITW Performance Polymers is an international leader in structural adhesives, grouting and chocking compounds, and wear-resistant coatings and repair products. Contact us to learn more about these products and their applications.