The Global EV Battery Encapsulation Foam Market was valued at USD 980 Million in 2025 and is projected to reach USD 2.8 Billion by 2034, growing at a Compound Annual Growth Rate (CAGR) of 12.4% during the forecast period (2024–2034). This remarkable growth is fueled by the explosive expansion of the electric vehicle industry, stringent safety and thermal management regulations, and the accelerating adoption of high-performance foam materials to protect next-generation battery packs.

As the automotive world shifts decisively toward electrification, the critical role of battery safety and longevity has come into sharp focus. EV battery encapsulation foam is a specialized material that provides vital functions including thermal insulation, mechanical cushioning, fire resistance, and protection against moisture and vibration. In this blog, we profile the Top 10 Companies in the EV Battery Encapsulation Foam Industry—a group of chemical innovators and material scientists ensuring the safety and reliability of millions of electric vehicles worldwide.

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EV Battery Encapsulation Foam Market – View in Detailed Research Report

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🔟 1. Rogers Corporation

Headquarters: Chandler, Arizona, USA
Key Offering: BISCO® Silicone Foams, PORON® Polyurethane Foams

Rogers Corporation is a global leader in engineered materials, with a particularly strong portfolio for EV battery systems. Their high-performance BISCO® silicone foams are renowned for exceptional thermal stability, flame retardancy, and compression set resistance, making them ideal for encapsulating large-format lithium-ion battery modules.

Innovation & Market Position:

• Proven track record with major OEMs like Tesla, GM, and Volkswagen

• Advanced formulations for cell-to-pack (CTP) and cell-to-chassis (CTC) battery designs

• Significant R&D investments in lightweight, high-resilience foam solutions

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9️⃣ 2. DuPont (Dow)

Headquarters: Wilmington, Delaware, USA
Key Offering: BETATECH™ Thermal Interface Materials, DuPont™ Styrofoam™ Brand Foams

Following the DowDuPont merger and subsequent splits, DuPont retains a formidable presence in high-performance materials. Their materials science expertise is critical for developing encapsulation foams that manage heat, suppress flames, and absorb impact within the challenging environment of an EV battery pack.

Innovation & Market Position:

• Comprehensive portfolio of silicones and engineered polymers

• Strong partnerships with automotive Tier-1 suppliers globally

• Focus on sustainability with recyclable and bio-based material options

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8️⃣ 3. BASF

Headquarters: Ludwigshafen, Germany
Key Offering: Elastoflex® Polyurethane Foams, Elastosorb® Foams

BASF, the world’s largest chemical producer, offers a wide array of polyurethane systems specifically designed for EV battery encapsulation. Their Elastoflex® foams provide excellent adhesion, vibration damping, and thermal properties, catering to the rigorous demands of automotive applications.

Innovation & Market Position:

• Global production network ensuring supply chain resilience

• Integrated solutions from raw materials to formulated systems

• Leadership in developing flame-retardant (UL94 V-0) foam grades

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7️⃣ 4. Henkel AG & Co. KGaA

Headquarters: Düsseldorf, Germany
Key Offering: Loctite® EA 9400 Series Encapsulants, Technomelt® Foams

Henkel is a powerhouse in adhesives and functional coatings, with a dedicated focus on e-mobility. Their encapsulation solutions are designed to protect battery cells from mechanical stress, thermal runaway propagation, and environmental factors, thereby extending battery life and enhancing safety.

Innovation & Market Position:

• Leading provider of thermally conductive encapsulation materials

• Extensive global technical service and application engineering support

• Commitment to developing fast-curing and easy-to-process formulations

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

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6️⃣ 5. Sika AG

Headquarters: Baar, Switzerland
Key Offering: SikaBiresin® Systems, SikaForce® Encapsulation Foams

Sika specializes in sealing, bonding, damping, and reinforcing solutions for the transportation industry. Their encapsulation foams are engineered for high durability, excellent adhesion to various substrates, and superior performance under thermal cycling, which is critical for battery pack longevity.

Innovation & Market Position:

• Strong presence in Asia-Pacific, a key EV manufacturing hub

• Focus on lightweighting solutions to maximize vehicle range

• Acquisition strategy to bolster e-mobility capabilities

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5️⃣ 6. Wacker Chemie AG

Headquarters: Munich, Germany
Key Offering: SILMATE® Silicone Encapsulants, ELASTOSIL® Foams

Wacker is a global leader in silicone chemistry, and its high-consistency rubber (HCR) and liquid silicone rubber (LSR) foams are increasingly used for battery encapsulation. These materials offer outstanding temperature resistance (from -50°C to +200°C) and long-term stability.

Innovation & Market Position:

• Pioneer in platinum-catalyzed, addition-cure silicone foams

• Customizable foam density and compression properties

• Strategic focus on the Chinese and European EV markets

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4️⃣ 7. Sekisui Chemical Co., Ltd.

Headquarters: Osaka, Japan
Key Offering: SLA Series Silicone Foams, Polyurethane Foam Sheets

Sekisui Chemical is a prominent Japanese manufacturer with advanced capabilities in foam processing. Their products are known for high quality and consistency, meeting the stringent requirements of Japanese and Korean automotive OEMs who are leaders in battery technology.

Innovation & Market Position:

• Strong R&D in flame-retardant and low-smoke emission foams

• Established supplier to battery giants like Panasonic, LG Energy Solution, and Samsung SDI

• Vertically integrated manufacturing from polymers to finished foam products

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3️⃣ 8. Saint-Gobain

Headquarters: Courbevoie, France
Key Offering: NORFOAM® Silicone Sponges, Polyurethane Foam Tapes

Saint-Gobain’s performance plastics division produces a range of foam materials used for gasketing, sealing, and cushioning in battery packs. Their NORFOAM® silicone sponges provide excellent compression recovery and environmental sealing, critical for protecting battery modules.

Innovation & Market Position:

• Global manufacturing footprint supporting just-in-time delivery to gigafactories

• Expertise in composite materials for multi-functional applications

• Focus on developing sustainable and recyclable foam products

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2️⃣ 9. 3M Company

Headquarters: Saint Paul, Minnesota, USA
Key Offering: 3M™ Silicone Foam Tapes, Polyurethane Foam Adhesives

3M’s diverse technology platform includes a wide array of adhesive tapes and foam materials ideal for battery encapsulation. Their double-sided foam tapes facilitate efficient assembly while providing thermal and dielectric insulation between battery cells and modules.

Innovation & Market Position:

• Innovator in pressure-sensitive adhesive (PSA) foam tapes

• Extensive testing and validation support for automotive qualifications

• Strong brand recognition and trust among OEMs and suppliers

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1️⃣ 10. Elkem Silicones

Headquarters: Oslo, Norway
Key Offering: Silbione® Silicone Elastomers, Specialty Silicone Foams

Elkem Silicones, one of the world’s fully integrated silicone producers, offers tailored solutions for EV battery systems. Their silicone foams are valued for their inherent flame resistance, flexibility at low temperatures, and excellent electrical insulation properties.

Innovation & Market Position:

• Investment in expanding silicone capacities to meet EV demand

• Development of thermally conductive yet electrically insulating foams

• Strategic focus on the North American and European markets with local technical centers

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

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🔋 Outlook: The Future of EV Battery Encapsulation Is Smarter and Safer

The EV battery encapsulation foam market is undergoing a profound transformation. While traditional materials continue to serve, the industry is rapidly innovating with multi-functional composites, smart foams with sensing capabilities, and sustainable material cycles.

📈 Key Trends Shaping the Market:

• Shift toward silicone foams for superior high-temperature performance and flame retardancy

• Integration of phase change materials (PCMs) within foams for passive thermal management

• Development of low-density formulations to reduce overall battery pack weight and increase vehicle range

• Rising demand for form-in-place (FIP) gasketing foams that enable automated, high-volume production

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

The companies profiled above are not merely suppliers of materials; they are essential innovation partners, enabling the safe, reliable, and mass-scale adoption of electric vehicles by securing the heart of every EV—its battery.