Custom Die-Cut EV & Battery Materials · For battery pack, powertrain & vehicle engineers

Custom EV & Battery Material Solutions: Compression, Sealing, Thermal-Runaway, Insulation & Bonding

Wide reference photo of die-cut materials across an EV battery pack and vehicle: compression pads between cells, closed-cell silicone perimeter seals, a thermal-runaway fire barrier, polyimide and aramid dielectric insulation on a busbar, a thermal pad and acrylic foam bonding tape, illustrating the breadth of the EV and battery material vertical

H-O Products converts microcellular polyurethane, closed-cell silicone, kSil KSV-series V-0 silicone sponge, thermal and fire barriers, AeroZero polyimide-aerogel film (silicone-PSA films, low-outgassing acrylic grades, graphite-faced spreader films and multilayer fire-barrier laminates), polyimide film, aramid paper, thermal-pad, Gore ePTFE and acrylic foam tape into die-cut compression pads, perimeter seals, thermal-runaway and fire barriers, dielectric insulation and structural bonding parts for the electric-vehicle battery pack and the whole vehicle. Made to your drawing, under an ISO 9001:2015 certified quality management system in Winsted, Connecticut.

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The EV & Battery applications

Where do you need a converted part?

Every sub-application in the EV & Battery vertical, each its own page with the materials, failure modes and converting detail for its job.

Battery Pack · 6 applications
Wide reference photo of EV battery compression pads in application context – a prismatic-cell module stack showing die-cut microcellular polyurethane compression pads placed between cells and against the module end plate, illustrating the cell-to-cell and cell-to-module compression interface Battery pack · 01 Compression & Cushioning Pads that hold a controlled push-back force against cells as they breathe and swell, in microcellular polyurethane and silicone. Open page → Wide reference photo of EV battery module and frame seals in application context: closed-cell silicone and EPDM perimeter gaskets seated around a battery module frame and a coolant plate, with a Gore ePTFE pressure-relief vent disk, illustrating module-perimeter, coolant-system and pack-venting sealing roles Battery pack · 02 Module & Frame Sealing Module perimeter and frame seals, coolant-system sealing, and pack venting, in closed-cell silicone, EPDM and ePTFE. Open page → Wide reference photo of EV battery pack-closure seals in application context: a closed-cell silicone pack-lid perimeter gasket and a butyl moisture-barrier strip around a sealed battery pack housing, with a Gore ePTFE pressure-equalization vent, illustrating lid, service-access and moisture-barrier sealing Battery pack · 03 Pack Closure & Environmental Pack lid, cover and service gaskets, corrosion and moisture barriers, and IP-rated pack closure with venting. Open page → Wide reference photo of EV battery thermal-runaway and fire-protection materials in application context - thermal-barrier sheets and aerogel layers placed between prismatic and pouch cells and against module walls, illustrating cell-to-cell thermal isolation and pack fire protection Battery pack · 04 Thermal-Runaway & Fire Protection Barriers that slow cell-to-cell thermal-runaway propagation, in dedicated EV fire barriers, aerogel-class insulation and mica. Open page → Wide reference photo of EV battery electrical-insulation and busbar materials in application context - polyimide film wraps, aramid-paper barriers and glass-epoxy isolation plates on busbars and interconnects, illustrating high-voltage dielectric isolation in a pack Battery pack · 05 Electrical Insulation & Busbar Dielectric films and papers that isolate busbars and high-voltage interconnects, in polyimide film, aramid paper and PEEK. Open page → Wide reference photo of EV battery bonding and assembly materials in application context - acrylic foam tapes and transfer tapes bonding brackets and modules, with release liners and process aids, illustrating structural bonding and serviceable interfaces in a pack Battery pack · 06 Bonding & Assembly Service Structural and assembly tapes that mount, join and bond parts in the pack, in acrylic foam tape and multi-layer laminations. Open page →
High-Voltage System · 1 application
Wide reference photo of EV power-electronics thermal and EMI materials in application context – thermal interface pads and films under a power module baseplate, a conductive EMI gasket framing an inverter housing seam, and an environmental seal on a BMS enclosure, illustrating the thermal, EMI and sealing roles High-voltage system · 07 Power Electronics, BMS & Inverter Thermal interface, dielectric and EMI parts for the inverter, the BMS and power electronics, in thermal pads, graphite and EMI elastomers. Open page →
Powertrain · 1 application
Wide reference photo of EV powertrain insulation and sealing materials in application context – aramid-paper slot liners and slot wedges seated in a traction-motor stator, a polyimide film phase barrier, and a fluorosilicone gearbox seal, illustrating the insulation, sealing and thermal roles in an e-axle Powertrain · 08 Powertrain & e-Axle Sealing, insulation, thermal and bonding parts for the e-axle and powertrain, in silicone, polyimide, thermal pads and tapes. Open page →
Vehicle · 3 applications
Wide reference photo of EV body, trim and exterior materials in application context – anti-rattle felt and foam pads along an interior trim seam, an acrylic foam bonding tape behind an exterior badge, and an EPDM weatherseal on a door aperture, illustrating the BSR, bonding and sealing roles Vehicle · 09 Body, Trim & Exterior Bonding, sealing, NVH and gasket parts for the body, trim and exterior, in acrylic foam tape, foams and seals. Open page → Wide reference photo of ADAS sensor sealing and gasketing in application context: die-cut silicone environmental gaskets, conductive EMI gaskets and ePTFE vent patches arranged around a LiDAR housing, camera module and sensor-fusion ECU Vehicle · 10 ADAS Sensors & Electronics Sealing, bonding, thermal and EMI parts for ADAS sensors and vehicle electronics, in silicone, thermal pads and EMI elastomers. Open page → Wide reference photo of EV interior NVH, insulation and filtration parts in application context: die-cut microcellular polyurethane anti-rattle pads, polyimide foam HVAC duct insulation, reticulated foam filtration media and acoustic lining arranged around an EV interior trim and HVAC module Vehicle · 11 Interior & Cabin NVH, cushioning, sealing and trim parts for the interior and cabin, in foams, tapes and gaskets cut to the assembly. Open page →
Infrastructure · 1 application
Wide reference photo of EV charger thermal, EMI and sealing parts in application context: die-cut graphite and boron-nitride thermal interface pads, conductive EMI gaskets, EPDM enclosure seals and an ePTFE vent arranged around a DC fast-charge power module and EVSE enclosure Infrastructure · 12 EV Charging Infrastructure Sealing, thermal, dielectric and EMI parts for charging hardware and connectors, in silicone, thermal pads and insulation. Open page →
Grid Storage · 2 applications
Wide reference photo of BESS compression, thermal-isolation and fire-barrier parts in application context: die-cut microcellular polyurethane compression pads, aerogel thermal-isolation layers and fire-barrier sheets arranged around grid-scale battery modules and a rack enclosure Grid storage · 13 BESS Battery Energy Storage Compression, sealing, thermal-runaway and insulation parts for stationary battery energy storage, in the same converted material families. Open page → Aerial view of rows of containerized battery energy storage units beside a utility substation Grid storage · 14 BESS Container, PCS & Balance-of-Plant The full-system companion to the cell- and module-level page: fire-barrier and thermal-runaway layers, PCS thermal and EMI materials, 1000–1500 VDC busbar insulation, enclosure sealing and venting, and HVAC isolation, framed by UL 9540A and NFPA 855. Open page →
Related application overviews & capabilities
elastomer and sponge gaskets staged for an enclosure sealing application. Application overview Engineered Sealing & Gasketing Environmental, EMI and fluid gaskets cut from silicone, EPDM, sponge and foam to the sealing geometry. Open overview → Lithium battery pack module assembly representing the thermal interface, insulation and fire-barrier applications served by thermal materials. Application overview Thermal Management & Insulation Thermal interface, heat-spreading and high-temperature insulation parts for power and battery hardware. Open overview → dielectric barriers and insulation washers for high-voltage power equipment. Application overview Energy, Power & High-Voltage Dielectric films, papers and rigid laminates that isolate busbars, windings and high-voltage interconnects. Open overview → Acrylic foam bonding tape on a release liner, the fastener-replacement bonding family. Application overview Structural Bonding & Fastener Replacement Acrylic foam and transfer tapes that mount, join and bond parts in place of mechanical fasteners. Open overview → Vehicle suspension and driveline underbody, the vibration environment addressed by isolation, damping and cushioning materials. Application overview NVH, Shock & Vibration Control Engineered foams and isolators that manage controlled force, shock and vibration across the assembly. Open overview →
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Engineering resources for EV & battery

Selection guides, failure-mode notes, and project work from H-O engineering, matched to the applications on this page.

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Send a drawing, a system-manual page, or a spec section; partial information is welcome. We typically respond within one business day with a material-family recommendation, the vendor technical data sheet behind it, a prototype lead time, and an honest note on anything that needs a listing holder or a sealant maker rather than a converter.

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Typical response in one business day. Typical prototype lead time is 5–10 business days after drawing review, depending on material availability, tooling, and inspection requirements.

Send a drawing, BOM, or a description of the application and what the part must do, and an engineer responds within one business day with a material-family direction and the matching sub-application page.

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Explore the material library: Foam Materials

Last updated · Reviewed by H-O Products engineering (ISO 9001:2015 certified converter, Winsted, CT).