The Large-Scale Manufacturing of Polymer Dielectric Capacitors: Advancements and Challenges

Since the 18th century, capacitors have significantly advanced in theoretical research and industrial applications. With the increasing demand for high-performance capacitors, the focus on advanced materials and manufacturing techniques has become critical. This review aims to provide a comprehensive survey of polymer capacitors, emphasizing their manufacturing processes and the connection between theoretical research and practical applications. Beginning with the fundamental principles of dielectric materials and capacitor design, this review delves into key aspects such as material preparation, film fabrication, and capacitor assembly while addressing the challenges in scale-up manufacturing for practical usage. Special attention is given to the metallization and winding processes, as these are pivotal for ensuring high reliability and performance in polymer capacitors. Additionally, this review analyzes the growing market demand for capacitors with enhanced thermal stability and operational efficiency, identifying research directions to address current limitations. By integrating the latest advancements in high-temperature polymer dielectrics, this review aims to provide valuable insights for both academia and industry. Finally, a forward-looking perspective is provided on future development trends and the obstacles that lie ahead, emphasizing the necessity for stronger collaboration between research and industry to foster innovation in this vital field. © 2025 Wiley-VCH GmbH.