DIE-CUT PARTS FOR BATTERY & ENERGY STORAGE Prototype Quickly | Scale Reliably | Simplify Assembly | Support North American Supply Chains
As an ISO 9001:2015 Certified flexible materials converter specializing in high-volume, die-cut components, JBC Technologies helps battery and energy storage teams convert complex material challenges into scalable, production-ready components — supporting safety, reliability, manufacturability, and speed from prototype through high-volume production.
Using a breadth of vertically integrated converting processes, we convert flexible materials into custom components that help address the core challenges inside EV and ESS battery systems, including thermal runaway mitigation, dielectric isolation, compression management, vibration damping, environmental sealing, and long-term pack reliability.
Our team collaborates directly with your launch engineers to de-risk high-volume production and ensure scalable, cost-effective manufacturing.
One Converting Partner. Multiple Benefits.
Turn to JBC Technologies for more than just die-cut parts – work with JBC to:
Move Faster From Design Concept to Validated Part
through rapid prototyping, engineering trials, design review, and production planning.
Reduce Supplier Risk With a North American Converter
that can support scalable production, material sourcing, and repeatable quality.
Simpify Assembly With Production Ready Parts
kiss-cut, adhesive-backed, roll-fed, tabbed, or kitted die-cut components for manual or automated placement on your line.
Ask an Engineer: Answers to Commonly Asked Battery Energy Storage Converting Questions:
JBC has experience die-cutting a myriad of custom components found in and around the battery pack, including battery cell separators, compression pads, gaskets and seals, dielectric barriers, thermal runaway protection, heat spreaders, and more!
JBC has experience converting a wide range of battery and energy storage materials, including graphite, mica, aerogels, thermal interface materials (TIMs), electrical insulation papers and films, compression pads, thermal barriers, sealing materials, ceramic papers, polyimide films, and battery separator materials. Our expertise extends from prototype development through high-volume manufacturing for applications such as thermal management, electrical insulation, cell spacing, sealing, and battery safety.
Thin and brittle materials require specialized converting methods, tooling, and process controls. JBC utilizes precision rotary and platen die-cutting equipment, optimized material handling techniques, and design-for-manufacturability (DFM) reviews to minimize stress on fragile materials during processing. Our engineering team works closely with customers to ensure critical material properties, such as thermal performance, electrical insulation, and structural integrity, are maintained throughout the converting process and into production
Yes. JBC has experience converting battery separator materials, including custom separator membranes used in advanced battery technologies. Our engineering team evaluates each material's unique characteristics, such as thickness, porosity, and handling requirements, to develop a converting process that maintains critical functional properties while delivering precise, production-ready components. Whether supporting prototype development or scalable manufacturing, we work closely with customers to ensure separator performance is preserved throughout the converting process.
JBC’s rapid prototyping capabilities utilize our dieless and digital cutting machines to create quick-turn prototypes made from production-intent materials for fit, form, and function testing. These capabilities allow you to quickly validate your components' design and evaluate the materials you’ve selected before moving forward with a full-scale production run.
To perform a comprehensive feasibility review, we recommend providing part drawings or CAD files, material specifications, annual volume requirements, critical-to-function features, tolerance requirements, assembly considerations, and any performance or environmental requirements. The more information available early in the design process, the better our engineering team can identify opportunities to improve manufacturability, reduce cost, maximize material yield, and support future production scalability.
JBC mitigates contamination risk through disciplined manufacturing controls, lot traceability, material handling procedures, equipment maintenance programs, and quality management systems. Depending on the application and material sensitivity, we can implement additional controls to protect critical battery components from particulate contamination, handling damage, and foreign material introduction throughout the converting process. Our focus is on delivering consistent, high-quality parts that meet the requirements of demanding battery and energy storage applications.
Domestic content requirements vary by customer, program, and applicable regulations. JBC works closely with customers and material suppliers to identify sourcing options and provide documentation regarding material origin when required. During project development, our team can help evaluate supply chain considerations and recommend solutions that support domestic content objectives while meeting performance, quality, and scalability requirements.
Domestic Die-Cutting & Design for Manufacturability Ideally Suited for North American Battery Programs
Powered by a robust U.S.-based domestic supply chain, JBC supports custom die-cut components used across cell, module, pack, rack, and enclosure-level battery assemblies — helping teams manage heat, isolation, compression, sealing, vibration, and assembly efficiency across EV, grid, commercial, industrial, and residential energy storage systems.
High-volume, rotary die-cut lightweight, tight-tolerance parts for automated module/pack assembly
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Compression pads
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Heat spreaders
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Busbar insulators
Commercial & Industrial Energy Storage
Larger-format parts support mechanical stability, thermal performance, and efficient installation
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Fire barriers
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Gap pads
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Environmental seals
Long Duration & Grid Storage
Durable, large-format die-cut or digital-cut components for grid-scale systems
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Flow battery gaskets and seals
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Busbar Insulation
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Separators
Residential Energy Storage
Mid-size components where aesthetics, vibration control, and enclosure protection matter.
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Vibration isolation pads
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Enclosure gaskets, dielectric films
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fire barriers
Through capabilities like multi-material lamination with pressure‑sensitive adhesives, tight-tolerance die cutting, and design-for-manufacturability (DFM), JBC helps customers eliminate fasteners, reduce part count, improve assembly efficiency, and deliver more consistent thermal and electrical performance at scale.
Precision Die-Cut , Multi-Layered Components Energy Storage Solutions by Product
From adhesive-backed compression pads to thermal runaway prevention, JBC supports many diverse die-cut solutions in and around the battery.
Compression Pads & Cushioning Solutions
Function: Compression management, cushioning, vibration damping, and dimensional stability
Where used: Cell, module, and pack-level assemblies
Problem solved: Cell swelling, pressure variation, vibration, mechanical shock, housing movement, and damage to sensitive internal components
Gaskets and Seals
Function: Environmental sealing, gasketing, contaminant resistance, and enclosure protection
Where used: Pack housings, covers, lids, vents, access panels, interfaces, and enclosure-level assemblies
Problem solved: Moisture intrusion, dust, road salt, chemical exposure, corrosion risk, pressure leakage, and long-term performance degradation
Thermal Runaway Protection
Function: Heat shielding, propagation delay, flame barrier support, and thermal event protection
Where used: Between cells, above cells, around modules, near venting paths, under lids, and near sensitive electronics or pack structures
Problem solved: Cell-to-cell propagation risk, flame and hot particle exposure, heat transfer to adjacent components, and localized protection needs during thermal events
Heat Spreaders & Interface Materials
Function: Heat spreading, thermal interface support, hot spot reduction, and temperature balancing
Where used: Cell interfaces, module surfaces, cold plate interfaces, electronics-adjacent areas, and pack-level thermal pathways
Problem solved: Localized hot spots, uneven temperature distribution, thermal imbalance across modules, reduced thermal contact, and accelerated aging caused by concentrated heat
Dielectric Barriers & Shields
Function: Electrical insulation, dielectric isolation, arc reduction, and high-voltage protection
Where used: Busbars, cold plates, cell and module interfaces, pack-level shields, terminals, and tight-space high-voltage areas
Problem solved: Short circuits, unintended current flow, electrical arcing, heat generation, and exposure of conductive surfaces
Battery Energy Storage Materials: Peformance, Functions & Converting Considerations.
Material Function |
Example Materials |
Performance Role |
Converting Considerations |
|---|---|---|---|
Electrical Insulation / Dielectric Barriers |
Polyimide films such as Kapton®, PET films, polypropylene films, PTFE, flame-retardant polypropylene such as ITW Formex™, glass cloth electrical tapes, 3M™ FRB-NT flame barrier papers, polyester electrical tapes, Avery Dennison Volt-Tough™ pressure-sensitive adhesive tapes |
Helps isolate conductive surfaces, reduce arcing risk, protect high-voltage areas, and support dielectric separation between cells, modules, busbars, cold plates, and pack-level structures. |
Requires tight-tolerance cutting, clean edges, adhesive selection, liner strategy, registration control, and repeatable placement in tight spaces or high-voltage assemblies. |
Thermal Runaway / Flame Barrier Protection |
Aerogel blankets and composites, mica, ceramic papers and blankets, aramid papers/felts such as Nomex®, intumescent foams and coatings, 3M™ FRB-NT materials, AIS ContraFlame® materials, Saint-Gobain Norseal® TRP silicone foams, and other high-temperature insulating foams. |
Supports heat shielding, propagation delay, hot particle resistance, flame barrier performance, and protection of adjacent cells, modules, electronics, and pack structures during thermal events. |
Often requires multilayer lamination, controlled thickness, dust or fiber management, edge control, adhesive compatibility, part nesting, and part presentations that support automated installation. |
Compression / Cushioning / Mechanical Protection |
Morgan Thermal Ceramics EST™ compression papers, AIS ContraFlame® compression pads, Rogers Corporation PORON® polyurethanes and BISCO® silicone foams (BF-1000, HT-800), Saint-Gobain Norseal® microcellular polyurethane foams (PF20, PF100 series), and other high-temperature compressible foams. |
Helps manage cell swelling, maintain consistent pressure, damp vibration, absorb shock, protect sensitive components, and support dimensional stability over repeated charge/discharge cycles. |
Requires a combination of compression behavior and adhesive compatibility awareness, laminating, surface treatment, tight tolerance die cutting, and part presentation that supports repeatable high-volume assembly. |
Sealing / Gasketing / Environmental Protection |
Closed-cell foams, EPDM, neoprene, polyurethane foams, silicone, fluoroelastomers, Rogers BISCO® silicone foams, Saint-Gobain Norseal® silicone foams, acrylic and silicone pressure-sensitive adhesives, and flame-retardant adhesive systems such as Avery Dennison Flame Tough™ PSAs. |
Helps protect battery packs and enclosures from moisture, dust, road salt, chemical exposure, pressure leakage, and environmental conditions. |
Requires material selection based on compression set, thickness, chemical exposure, adhesive system and gasket geometry. Container-level and large module gaskets often require large-format digital or die cutting. Smaller gaskets require high-speed rotary or platen cutting.. |
Separator / Divider / Spacer Materials |
Freudenberg Performance Materials Nonwoven Battery Separators (including tailored wetlaid, drylaid, meltblown, and spunlaid matrices), ceramic-coated separator films, polyimide films, rigid plastics (polycarbonate, PEEK ) |
Supports spacing, isolation, mechanical protection, temperature resistance, and component separation depending on the battery architecture and location in the cell, module, or pack. |
Requires web handling or sheet handling appropriate to material format, burr and debris control, dimensional accuracy, hole/slot registration, material stability, and conversion methods matched to separator type, geometry, and thickness. |
Multi-Functional Laminates / Assembly-Ready Material Stacks |
Thermal interface materials, dielectric films, flame-barrier layers, compression foams, cushioning materials, graphite heat spreaders, nonwovens, foils, and pressure-sensitive adhesive systems used to build custom multi-layer constructions. |
Integrates bonding, insulation, thermal management, flame resistance, cushioning, spacing, sealing, or peel-and-place functionality into a single converted component. |
Requires material compatibility review, adhesive selection, lamination sequence design, thickness control, liner configuration, pull tabs, registration control, release strategy, and roll-fed, sheeted, or kitted formats for scalable production. |
Converting Battery Concepts into Reality From Application Challenge to Production-Ready Part
As a vertically integrated material solutions provider, JBC Technologies works with you from concept through production to optimize component designs for manufacturability and value.
When you are ready to scale, there is no better place to do it than with JBC.
Our Battery Energy Storage Converting Toolkit includes
Related Reading & Resources
Tackling Electrical and Thermal Runaway In Battery Storage
Are you having difficulty balancing cost, scalability, safety, and quality in your e-mobility or battery energy storage system (BESS) designs? Looking for a scalable solution for electrical insulation or thermal runaway mitigation? Join industry experts from 3M and JBC Technologies for a webinar that tackles these challenges and more.
Using Converting & Material Science to Mitigate Thermal Runaway in EV Batteries
Effective thermal management goes beyond simply maintaining uniform heat levels, it requires utilizing proper high-performance materials specifically engineered to mitigate thermal runaway between battery cells. In this Q&A featuring 3M material experts, we discuss how custom-converted thermal management materials enhance vehicle safety and consumer experience, all while reducing weight.
Performance Materials for Passive EV Battery Thermal Management
There is no one-size-fits-all solution to passive thermal management in EV batteries. Whether your goal is to insulate, spread, or shield heat, working with a converting partner is the key to engineering the perfect custom solution for your battery project. In this whitepaper, we highlight the different ways die-cut flexible materials solve passive thermal management challenges in and around the battery pack, helping increase battery safety, longevity, and performance.
The Impact of Die-Cut Adhesive Tapes on Cost-Effective Design and scalability in EV/BESS Markets
Battery manufacturers are always looking for ways to improve the weight, scalability, and cost of their battery designs. Unlike traditional mechanical fasteners or liquid adhesives, die-cut pressure-sensitive adhesives (PSAs) are a sleek, lightweight, scalable, and cost-effective solution to bonding and joining in and around the battery pack. Learn more about why battery engineers are utilizing PSAs in their battery design in this informative whitepaper.
Let us help you find solutions to:
PRevent short circuits and electrical arcing
boost overall pack integrity
Insulate and isolate battery cells
Improve battery longevity
mitigatE thermal Runaway
And much more
Here are just a few of the many material partners we work with:
Submit Your Battery Energy Storage Die Cutting Project
With over 35 years of experience finding engineered solutions to complex converting challenges, JBC Technologies is a partner you can trust for custom battery components. Built on our core foundation of engineering innovation, supply chain optimization, and manufacturing excellence, our approach encompasses these core value pillars:
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Engineering Collaboration and DFM
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Rapid Prototyping to Production Scale-Up
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Vertically Integrated High Volume Converting
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Quality and Reliability
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North American Supply Chain Resilience
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Assembly Optimization and Value-Added Services
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Value Analysis/ Value Engineering
Ready to work with an experienced die cutter that focuses on the total solution?