The Global Battery Encapsulation Foam Market was valued at USD 1.48 Billion in 2025 and is projected to reach USD 4.12 Billion by 2034, growing at a Compound Annual Growth Rate (CAGR) of 12.8% during the forecast period (2024–2030). This robust expansion is primarily fueled by the unprecedented global surge in Electric Vehicle (EV) production, increasingly stringent safety regulations for lithium-ion batteries, and the critical need for advanced thermal management solutions.

As the automotive industry accelerates its transition to electrification, the spotlight turns to the specialized materials that ensure battery pack integrity, safety, and longevity. Battery encapsulation foam is a pivotal component, providing essential functions such as cushioning against vibration, thermal insulation, flame retardancy, and structural support within battery modules. In this blog, we profile the Top 10 Companies in the Battery Encapsulation Foam Industry—a diverse group of chemical giants, specialty material suppliers, and foam technology innovators who are securing the future of electric mobility.

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🔟 1. BASF SE

Headquarters: Ludwigshafen, Germany
Key Offering: Elastoflex® polyurethane foams, Elastosorb® acoustic foams

BASF is a global leader in polyurethane chemistry and a major supplier of advanced foam systems for battery encapsulation. Their engineered foams offer excellent thermal stability, flame retardancy, and compressibility, making them ideal for protecting sensitive battery cells from mechanical stress and thermal runaway propagation.

Innovation & Sustainability Initiatives:

• Development of bio-based and recyclable polyol feedstocks for foam production.

• Collaborative R&D partnerships with major European and North American automotive OEMs.

• Focus on creating closed-loop recycling pathways for end-of-life EV battery foams.

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9️⃣ 2. Dow Chemical Company

Headquarters: Midland, Michigan, USA
Key Offering: SPECFLEX™ and VORANOL™ polyurethane systems, SILASTIC™ silicone foam

Dow offers a comprehensive portfolio of foam solutions for battery systems, leveraging its expertise in both polyurethanes and silicones. Their materials are designed to meet rigorous automotive standards for flame, smoke, and toxicity, providing a critical safety layer in high-energy-density battery packs.

Innovation & Sustainability Initiatives:

• Investment in silicone foam technology for high-temperature stability exceeding 200°C.

• Commitment to achieving carbon neutrality in its operations by 2050.

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8️⃣ 3. Rogers Corporation

Headquarters: Chandler, Arizona, USA
Key Offering: BISCO® silicone foams, PORON® polyurethane foams

Rogers Corporation specializes in high-performance engineered materials, with a strong focus on elastomeric foams for demanding applications. Their BISCO® silicone foams are particularly noted for their exceptional thermal resistance and integrity under compression, making them a preferred choice for sealing and cushioning within battery enclosures.

Innovation & Sustainability Initiatives:

• Product development focused on low outgassing formulations for sensitive battery environments.

• Expansion of manufacturing capacity in Asia to serve the growing EV market.

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7️⃣ 4. Sekisui Chemical Co., Ltd.

Headquarters: Osaka, Japan
Key Offering: Volara® and Minicel® cross-linked polyolefin foams

Sekisui Chemical is a leading global manufacturer of cross-linked polyolefin foams, which are widely used for gap filling, cushioning, and insulation in battery packs. Their closed-cell foams offer excellent resistance to chemicals and moisture, which is crucial for maintaining battery performance and preventing corrosion.

Innovation & Sustainability Initiatives:

• Development of flame-laminated foam tapes for simplified assembly processes.

• Initiatives to incorporate recycled content into foam products.

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Battery Encapsulation Foam Market – View in Detailed Research Report

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6️⃣ 5. Henkel AG & Co. KGaA

Headquarters: Düsseldorf, Germany
Key Offering: Loctite® EA 9400 series encapsulants, Technomelt® hot melt foams

Henkel provides a wide array of adhesive and functional coating solutions, including specialized foams and encapsulants for battery systems. Their products are engineered to provide robust thermal conductivity, electrical insulation, and protection against environmental factors like humidity and salt spray.

Innovation & Sustainability Initiatives:

• Strong focus on thermally conductive gap filler foams to manage heat dissipation.

• Commitment to sustainability through products that enable lighter-weight vehicle designs.

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5️⃣ 6. Saint-Gobain

Headquarters: Courbevoie, France
Key Offering: CERTAINTEED® and NORPRO® high-temperature foam solutions

Saint-Gobain leverages its deep materials science expertise to produce advanced foam materials for thermal and acoustic management in EVs. Their solutions are designed to withstand the harsh operating conditions of battery packs while contributing to passenger safety and comfort.

Innovation & Sustainability Initiatives:

• R&D into ceramic and silica-based aerogel foams for ultra-high-temperature insulation.

• Integration of recycled glass and other materials into foam production processes.

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4️⃣ 7. Wacker Chemie AG

Headquarters: Munich, Germany
Key Offering: SILMOTION® and ELASTOSIL® silicone foams

Wacker is a leading global producer of silicones, offering high-performance silicone foams that remain flexible and stable across a wide temperature range (-60°C to +200°C). Their materials are essential for fire-blocking seals and cushioning components that prevent thermal runaway from spreading between battery cells.

Innovation & Sustainability Initiatives:

• Pioneering solvent-free and platinum-catalyzed silicone foam technologies.

• Development of foams with enhanced thermal conductivity for better heat management.

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3️⃣ 8. Recticel NV/SA

Headquarters: Brussels, Belgium
Key Offering: Engineered polyurethane and polyisocyanurate foams

Recticel is a European specialist in flexible and rigid foam solutions, with a growing business unit dedicated to automotive applications. Their foams for battery encapsulation are formulated to meet specific density, compression set, and flame retardancy requirements set by global car manufacturers.

Innovation & Sustainability Initiatives:

• Investment in water-blown foam technology to reduce environmental impact.

• Collaboration with battery module manufacturers to develop custom foam designs.

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2️⃣ 9. Evonik Industries AG

Headquarters: Essen, Germany
Key Offering: ROHACELL® structural foam, VESTAMID® specialty polyamides

While renowned for its ROHACELL® PMI foam used in composite cores, Evonik also provides advanced material solutions that contribute to battery safety. Their expertise in high-performance polymers enables the development of components that offer a unique combination of light weight, strength, and thermal stability for battery housings and internal structures.

Innovation & Sustainability Initiatives:

• Research into foam-integrated phase change materials (PCMs) for passive thermal management.

• Sustainability strategy focused on circular economy principles and carbon reduction.

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1️⃣ 10. Inoac Corporation

Headquarters: Tokyo, Japan
Key Offering: Polyurethane, polyolefin, and rubber foams for automotive

Inoac is a key Japanese supplier of plastic and foam products, with a significant presence in the automotive sector. The company provides a variety of foam-based solutions for battery padding, sealing, and insulation, catering to the specific needs of Asian EV manufacturers with a focus on precision and reliability.

Innovation & Sustainability Initiatives:

• Development of lightweight, multi-functional foam components to reduce part count.

• Active participation in industry consortia to standardize battery safety materials.

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Battery Encapsulation Foam Market – View in Detailed Research Report

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🌍 Outlook: The Future of Battery Encapsulation Is Smarter and Safer

The battery encapsulation foam market is evolving rapidly, moving beyond basic cushioning to become an intelligent, multi-functional component of the battery system. As energy densities increase and battery designs become more complex, the demand for foams that actively contribute to safety, thermal management, and structural integrity will intensify.

📈 Key Trends Shaping the Market:

• Integration of Phase Change Materials (PCMs) within foam matrices for enhanced passive thermal regulation.

• Rise of dual-duty foams that provide both fire protection and exceptional acoustic damping.

• Growing adoption of polyurethane foam, which holds the largest market share due to its versatility and cost-effectiveness.

• Increased regulatory focus on flame, smoke, and toxicity (FST) standards globally, driving innovation in material formulations.

The companies profiled above are not just supplying materials; they are active partners in the electrification revolution, developing the critical safety solutions that will enable the next generation of clean transportation.

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