Custom Die-Cut TIMs and Heat Spreaders for EV, BESS, and Data Center Battery Systems
As EV battery packs, stationary energy storage systems, and backup power systems become more compact and power dense, engineers need thin, lightweight thermal components that help move heat efficiently without adding unnecessary bulk.
Using our vertically integrated die-cutting and flexible materials converting capabilities, and ISO 9001:2015 certified quality framework, JBC Technologies transforms these thin, lightweight thermal materials into custom assembly-ready components that help support consistent cell temperatures and fit demanding battery pack geometries.
Thermal Interface and Heat Spreading Materials for Battery Systems
Materials Built for Everyday Thermal Control
Thermal interface and heat spreading materials are used across EV battery systems, long-duration grid storage, commercial and industrial battery storage, residential backup systems, and high-power environments such as data centers to help manage heat generated during charging, discharging, fast charging, and routine power delivery.
The material is only part of the solution, however. You need a top-tier flexible material converter like JBC Technologies to transform these specialty materials into custom, production-ready parts for easy assembly on your line.
Thermal Interface Materials
including gap pads, thermal interface films, thermally conductive adhesives, and phase change materials, help improve contact between surfaces so heat can move more efficiently into a cooling path.
Heat spreading materials
including flexible graphite, copper foils, aluminum foils, and thermally conductive laminates, help move heat laterally across compact spaces to reduce localized hot spots.
Dielectric films and insulating layers
can be incorporated where electrical isolation is needed between conductive battery components, thermal materials, trays, enclosures, or electronics.
Converted multi-layer constructions
can combine thermal, dielectric, adhesive, liner, and protective layers into one assembly-ready component.
Custom Converted Components Designed to Manage Everyday Battery Heat
Leaning into our three pillars of engineering innovation, supply chain optimization, and manufacturing excellence, JBC Technologies helps engineers turn their die-cut passive thermal management component design concepts into repeatable, assembly-ready parts that...
Improve Thermal Contact
Thermal interface components help improve surface contact where air gaps can limit heat transfer. JBC converts these materials into custom die-cut parts that fit between battery cells, modules, cold plates, heat sinks, trays, and enclosures.
Spread Heat Across Tight Spaces
Thin heat-spreading materials help move heat laterally across compact assemblies. JBC converts heat-spreading materials into parts that fit around battery cell tabs, busbars, electronics, and enclosure features.
How We Transform Thermal Materials into Production-Ready Components
Leveraging years of process engineering expertise and advanced converting capabilities, we transform flexible materials into custom high-performance components that are greater than the sum of their parts.
From early design validation to production-ready parts, we provide the technical know-how and responsiveness to help engineers launch quickly and simply their supply chain.
Turn to JBC Technologies for...
Rapid Prototyping
Dieless cutting methods, including laser, waterjet, CNC, and reciprocating knife cutting, support fast iteration, material validation, and fit, form, and function testing.
Precision Die-Cutting
High-volume die cutting supports repeatable thermal components with inline adhesive integration and part presentation options for automated assembly.
Clean Room Die-Cutting
ISO Class 8 cleanroom converting supports controlled processing, clean packaging, kitting, and multi-station rotary production.
Ancillary Converting Functions
Laminating, slitting, embossing, micro-perforating, ultrasonic welding, and surface treatment help create more complete, assembly-ready component constructions.
Ask An Engineer: Thermal Interface and Heat Spreading Converting FAQs
Flexible graphite is exceptionally thin, soft, and fragile, making it prone to tearing, stretching, particle generation, and handling damage during converting. JBC Technologies has extensive experience processing flexible graphite into precision die-cut components, including multi-layer laminates with adhesives and dielectric films. Our engineering team develops material-specific converting methods that protect material integrity, maximize yield, and ensure consistent part quality for demanding thermal management applications.
When applications require additional protection, JBC can provide envelope edge sealing or encapsulation solutions that contain graphite edges, reduce particle generation, improve handling, and protect the material during assembly and use. The sealing approach is selected based on the application's thermal, environmental, and assembly requirements.
Tolerance capability is highly dependent on the material thickness, density, and compressibility. Softer, thicker thermal gap pads naturally have more dimensional variation than firm films or foils. Our engineering team reviews each design and material combination to establish realistic manufacturing tolerances and ensure production capability aligns with application requirements before launch.
Yes. JBC offers both island placement and selective adhesive lamination solutions. These techniques allow adhesives or high-value materials to be applied only where needed, reducing material costs, improving assembly performance, and preventing adhesive interference in critical areas. The process is customized based on part geometry, material characteristics, and downstream assembly requirements.
Absolutely. We regularly incorporate pull-tabs, extended liners, split liners, and butterfly-style constructions to simplify part handling and assembly. These features help operators and automated equipment remove liners more efficiently, improve placement accuracy, and reduce assembly time.
Yes. JBC frequently designs parts for robotic and automated assembly systems. We optimize part presentation through features such as kiss-cut roll formats, controlled part spacing (pitch), extended liners, pull-tabs, slug removal, and zoned adhesive configurations. By understanding your automation process early in development, we can tailor the converted part and packaging format for reliable pick-and-place performance.
Material yield optimization begins during design review. Our engineers evaluate material cost, nesting efficiency, part geometry, adhesive construction, and manufacturing method to identify the most economical conversion approach. We leverage specialized die-cutting, lamination, and material transfer techniques to minimize waste, reduce scrap, improve throughput, and maximize value, particularly when converting expensive thermal materials such as flexible graphite and specialty gap pads.
On Demand Webinar
Overcoming Thermal and Electrical Challenges with Advanced Materials Converting
Discover how to solve critical battery issues—including thermal runaway, electrical arcs, short circuits, and vibration damage—with advanced engineered materials, pressure-sensitive adhesives, and precision die-cutting. Join industry experts from JBC Technologies and Avery Dennison Performance Tapes to learn how to:
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Maximize Advanced Materials: Tap into the potential of next-generation material solutions.
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Elevate Safety & Performance: Leverage specialized tapes to protect and enhance your designs.
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Drive Thermal & Electrical Efficiency: Optimize battery performance using innovative material science.
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Scale Production: Streamline your manufacturing processes and improve overall yield.
Related Reading... Thermal Interface Materials
Your Partner. For Die-Cut EV Battery Thermal Interface and Heat Spreading Solutions
As an ISO 9001:2015 certified 3M™ Preferred Converter with multiple North American manufacturing locations, JBC Technologies helps turn thermal materials into production-ready battery components. We can combine thermal materials with adhesives, liners, dielectric films, or protective layers, then die cut them to meet your specific form, fit, and function requirements.
The result is a custom component that is easier to handle, place, and scale from prototype through high-volume production. Talk to JBC about your thermal interface or heat spreading application and let us help you move from material selection to an assembly-ready solution.