The Global EV Battery Polyurethane Foam Market was valued at USD 1.25 Billion in 2025 and is projected to reach USD 3.42 Billion by 2034, growing at a Compound Annual Growth Rate (CAGR) of 13.8% during the forecast period (2024–2030). This robust growth is fueled by the global surge in electric vehicle (EV) production, escalating demand for enhanced battery safety and thermal management, and stringent regulatory standards for vehicle crashworthiness and fire prevention.

As the automotive industry undergoes a profound shift toward electrification, the critical role of advanced materials in ensuring battery pack integrity, longevity, and performance has come to the forefront. Polyurethane foam is a key enabler, providing essential properties like vibration damping, thermal insulation, and flame retardancy. In this blog, we profile the Top 10 Companies in the EV Battery Polyurethane Foam Industry—a mix of chemical giants, specialty material suppliers, and innovative foam manufacturers shaping the future of EV safety and efficiency.

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EV Battery Polyurethane Foam Market – View in Detailed Research Report

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🔟 1. Sekisui Chemical Co., Ltd.

Headquarters: Osaka, Japan
Key Offering: High-performance polyurethane foams for battery cushioning and gap fillers

Sekisui Chemical is a leading global chemical company with a strong portfolio of advanced polyurethane systems tailored for the EV battery market. Their specialty foams are engineered for excellent compressibility and recovery, providing reliable cushioning and shock absorption for sensitive battery cells within modules and packs.

Innovation and Strategic Focus:

• Development of low-density, high-resilience foams for weight reduction

• Focus on flame-retardant formulations meeting international safety standards (UL94, etc.)

• Strategic partnerships with major Asian and global automotive OEMs

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9️⃣ 2. Inoac Corporation

Headquarters: Nagoya, Japan
Key Offering: Custom-molded polyurethane foam components for battery packs

Inoac is a premier supplier of polymer products, including a wide range of polyurethane foams for automotive applications. The company specializes in designing and manufacturing precise foam components that serve as seals, gaskets, and cushioning materials within EV battery assemblies, ensuring protection against environmental ingress and mechanical stress.

Innovation and Strategic Focus:

• Advanced molding technologies for complex foam geometries

• Materials with integrated thermal management properties

• Global production footprint to support Just-In-Time delivery to automakers

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8️⃣ 3. Daicel Corporation

Headquarters: Osaka, Japan
Key Offering: Flame-retardant polyurethane foams and plastic foaming agents

Daicel Corporation leverages its expertise in chemical engineering to produce specialized flame-retardant additives and polyurethane foam systems. Their products are critical for enhancing the fire safety of EV battery packs, helping to mitigate thermal runaway risks and meet stringent automotive safety regulations.

Innovation and Strategic Focus:

• Proprietary flame-retardant technologies for polyurethane matrices

• R&D into foam systems that provide both thermal insulation and fire resistance

• Collaboration with battery manufacturers on next-generation safety solutions

Download FREE Sample Report:
EV Battery Polyurethane Foam Market – View in Detailed Research Report

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7️⃣ 4. Henkel AG & Co. KGaA

Headquarters: Düsseldorf, Germany
Key Offering: LOCTITE® polyurethane foams for battery potting and encapsulation

Henkel is a global leader in adhesive technologies, and its LOCTITE brand offers high-performance polyurethane foam systems designed for EV battery applications. These foams are used for potting and encapsulating battery modules, providing excellent protection against vibration, moisture, and thermal fluctuations.

Innovation and Strategic Focus:

• Two-component PU foam systems for automated dispensing

• Foams with low exotherm during curing to protect sensitive electronics

• Global technical support network for automotive OEMs and tier suppliers

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6️⃣ 5. Saint-Gobain

Headquarters: Courbevoie, France
Key Offering: Specialty polyurethane foams for thermal and acoustic management

Saint-Gobain provides advanced material solutions, including polyurethane foams that contribute to the thermal and acoustic insulation of EV battery systems. Their products help maintain optimal battery operating temperatures while reducing noise and vibration from the battery pack.

Innovation and Strategic Focus:

• Development of multi-functional foam solutions

• Focus on sustainability with bio-based polyol options

• Integration with other Saint-Gobain materials for complete battery system solutions

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5️⃣ 6. Prostech

Headquarters: Suzhou, China
Key Offering: Custom-engineered PU foam components for EV batteries

Prostech is a specialized manufacturer of polyurethane products, focusing on the rapidly growing Chinese and Asian EV markets. The company produces a variety of foam parts, including gap fillers, seals, and cushioning pads, tailored to the specific requirements of different battery designs and chemistries.

Innovation and Strategic Focus:

• Rapid prototyping and customization for EV startups and established OEMs

• Cost-effective manufacturing solutions for high-volume production

• Strong focus on quality control and meeting automotive industry standards

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4️⃣ 7. Rogers Corporation

Headquarters: Chandler, Arizona, USA
Key Offering: BISCO® silicone and polyurethane foams for battery isolation and cushioning

Rogers Corporation is a renowned engineered materials company offering high-performance foam solutions. Their BISCO® brand includes specialty polyurethane foams that provide critical vibration damping and isolation within battery packs, protecting cells from mechanical shock and extending battery life.

Innovation and Strategic Focus:

• High-performance foams with consistent cell structure and durability

• Materials capable of withstanding extreme temperatures and compression sets

• Comprehensive testing and validation services for automotive applications

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3️⃣ 8. Evonik Industries AG

Headquarters: Essen, Germany
Key Offering: Polyurethane additives and specialty foams for lightweighting and safety

Evonik is a global specialty chemicals leader, supplying key raw materials and additives for producing high-quality polyurethane foams. Their expertise helps foam manufacturers develop products with enhanced properties, such as improved flame retardancy, lower density, and better thermal stability for EV battery applications.

Innovation and Strategic Focus:

• Development of sustainable polyols and isocyanates

• Additives to improve the fire performance of PU foams

• Collaborative R&D projects with partners across the EV value chain

Download FREE Sample Report:
EV Battery Polyurethane Foam Market – View in Detailed Research Report

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2️⃣ 9. 3M Company

Headquarters: Saint Paul, Minnesota, USA
Key Offering: Versatile polyurethane foam tapes and gap fillers

3M offers a diverse portfolio of adhesive tapes and non-adhesive foam products used in EV battery manufacturing. Their polyurethane foam tapes provide strong bonding and sealing solutions for battery housings, while bulk gap-filling foams help manage tolerances and absorb shocks within the pack assembly.

Innovation and Strategic Focus:

• Acrylic and PU foam tapes with high bond strength and environmental resistance

• Focus on ease of application and automation compatibility

• Global supply chain and technical expertise supporting automotive innovation

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1️⃣ 10. H.B. Fuller Company

Headquarters: Saint Paul, Minnesota, USA
Key Offering: Polyurethane foam adhesives and sealants for battery assembly

H.B. Fuller is a leading global adhesives provider, supplying polyurethane-based foam adhesives and sealants used in constructing and sealing EV battery packs. These products create robust, durable bonds between battery components and provide essential environmental protection.

Innovation and Strategic Focus:

• Formulations with fast cure times for high-throughput manufacturing

• Products designed for compatibility with various substrates (metals, plastics)

• Commitment to developing more sustainable adhesive solutions

Get Full Report Here:
EV Battery Polyurethane Foam Market – View in Detailed Research Report

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🔋 Outlook: The Future of EV Battery Polyurethane Foam Is Smarter and More Sustainable

The EV battery polyurethane foam market is evolving rapidly, driven by the need for higher energy density batteries, improved safety protocols, and greater manufacturing efficiency. Material innovation is central to achieving these goals, with a clear trend toward multi-functional and intelligent foam systems.

📈 Key Trends Shaping the Market:

• Development of Phase Change Material (PCM)-integrated foams for passive thermal management

• Increasing use of bio-based and recycled content in polyol feedstocks to enhance sustainability

• Rise of foam-based fire barrier systems designed to contain thermal runaway events

• Adoption of lightweighting strategies where foam density is optimized without compromising performance

Get Full Report Here:
EV Battery Polyurethane Foam Market – View in Detailed Research Report

The companies listed above are not only supplying essential components—they are integral partners in enabling the safe, reliable, and mass adoption of electric vehicles worldwide.