The Latest Technological Breakthroughs in Film Capacitors in 2025: Enabling New Energy And Electronic Equipment Upgrades

With the rapid development of new energy vehicles, photovoltaic wind power and other emerging industries, as the core components of electronic circuits, film capacitors, their technological innovation and performance upgrades have become the focus of industry attention. Recently, after ZZEC technical report shows that film capacitors in the material, process and functional integration and other areas have made a number of breakthroughs, for the expansion of downstream application scenarios to provide key support.

I. Manufacturing process optimization: metallized film technology continues to upgrade, performance and reliability of the double enhancement
The core manufacturing process of film capacitors is divided into traditional metal foil process and metallized film process. At present, the metallized film process (metal electrode formed on the surface of the base film by vapor deposition of aluminum or zinc) has become the mainstream. According to the "Analysis of Development Status and Competitive Landscape of China Film Capacitor Industry" released in March 2025, the thickness reduction of base film materials (such as polypropylene PP, polyester PET) and the fine control of evaporation technology have become the key to improve the quality of film capacitors. For example, the new metallized film process reduces the capacitor's high-frequency loss (ESR) by 15% and extends its life by 20% by optimizing the evaporation uniformity, resulting in more stable performance in high-voltage and high-frequency scenarios such as new energy vehicle inverters and photovoltaic inverters.

Second, material innovation: miniaturization, environmental protection to lead the trend
Advances in materials science have pushed film capacitors toward higher performance and miniaturization. 2025 industry report released in February pointed out that capacitors using new dielectric materials (such as low dielectric loss polyphenylene sulfide PPS, high temperature resistant polyethylene naphthalene dicarboxylate PEN) can be reduced in size by 30% while ensuring high reliability, and are suitable for 5G communication devices, wearable electronics and other space-critical scenarios. space-critical scenarios such as 5G communication devices and wearable electronics. In addition, the research and development of environmentally friendly materials is accelerating, and the proportion of halogen-free and low-toxicity films has been increased from 12% in 2023 to 25% in 2025, which is in line with the demand for green manufacturing under the global "dual-carbon" goal.

Third, market-driven: new energy and electronic equipment demand surge, accelerated technology iteration
Currently, the global film capacitor market continues to expand. According to market research data, the global market size of about 3.2 billion U.S. dollars in 2021, is expected to reach 5.2 billion U.S. dollars in 2025 (compound annual growth rate of 12.91%). As the world's largest producer and consumer, China's demand for film capacitors in 2023 has reached 106.37 billion, with demand outstripping supply. Explosive growth in new energy vehicles (inverters, vehicle charging OBCs), photovoltaic wind power (converters) and 5G communications has become the core driver of technology iteration. For example, new energy vehicle sales are expected to account for 20% in 2025 (more than 5 million units), and its demand for high-voltage, long-life film capacitors increased by 30% year-on-year, driving companies to accelerate the layout of high-end product lines.