The growing number of electric vehicles (EVs) and the integration of more renewable electricity into power grids is opening a new segment of the nonwovens market that is both highly specialized and lucrative.

A new market report from Smithers—The Future of Nonwoven Battery Separators to 2030—shows that in 2025, global demand for nonwoven battery separators worldwide will reach $1.7 billion, and consume 155,600 tons of nonwovens.

Further investment in new battery technologies for EVs, consumer electronics and distributed energy infrastructure will see volume demand accelerate at 12.5% year-on-year to 280,000 tons in 2030. Across the same period value will more than double, reaching $3.98 billion (at constant pricing).

Unlike familiar mass market applications for nonwovens, this is a technically demanding segment, making it more difficult to penetrate.

The principal nonwovens used in batteries are wetlaids. As high-performance durable nonwovens these grades use high volumes of more expensive raw materials, including polyamide and specialty fibrillated lyocell—a typical construction might be a wetlaid lyocell-polyester-polyamide structure.

There are also competing materials for battery construction, mainly polymer film separators, while specialty papers have their own, small, market share. Nonwovens account for 21.3% of current battery separator sales, but for designers the latest grades offer distinct advantages—better management of higher energy densities, improved safety and lighter overall weight.

Representing 70.2% of this market volume, wetlaid nonwovens are used with most major battery chemistries. Critically they are the only grade suitable for the lithium-ion cells preferred for EVs and modern energy storage. This is a quickly developing segment that is rewarding investment in improved components including nonwoven grades.

Annual sales of nonwoven separators for lithium-ion batteries are projected to reach $666 million in 2025 and will then grow at 31.3% year-on-year through to 2030—more than quadrupling in value over this period and increasingly dominating the sector. This is partially because lithium-ion batteries are much larger than conventional batteries. A lithium-ion EV battery requires an average of 700 square meters of separator material; in contrast, a nickel-cadmium battery for a consumer camera might require as little as 0.002 square meters.

Consequently, wetlaid nonwovens will further increase their market share by both volume and value across the wider market. While needlepunch, carded and spunlace grades are all available, they will remain confined to nickel-metal hydride batteries, a much less dynamic technology.

The Future of Nonwoven Battery Separators to 2030 provides expert analysis of the current and future demand for these materials; quantifying it in a data set segmented by raw material, nonwoven type, battery chemistry, end-use application, and geographic region


In The News

Alkegen Expands Production: Alkegen, a supplier of cell spacers, announced the full-scale commercial production of its proprietary fiber-enhanced aerogel insulation for electric vehicle (EV) battery fire protection.

This launch marks Alkegen’s strategic product portfolio expansion for the EV market, delivering a comprehensive portfolio of advanced thermal and electrical insulation materials for original equipment manufacturers (OEMs). With the addition of aerogels to
its offering, Alkegen now provides OEMs with end-to-end insulation solutions optimized for performance, design flexibility and scalable production.

“We’ve taken a platform that’s already proven itself in the industrial space and scaled it for one of the fastest-growing markets in the world—EV battery safety,” says Alkegen CEO John Dandolph. “Automakers no longer have to rely on a single supplier in North America for this mission-critical solution.”

At the heart of this expansion is AlkeGel, Alkegen’s next-generation, high-performance fiber-aerogel composite, engineered to meet OEM demand for ultra-thin, safe, and easy-to-install thermal runaway protection for lithium-ion battery systems. Unlike traditional aerogels, AlkeGel is low-dust, eliminating the need for full encapsulation and allowing for simpler and more cost-effective part designs that integrate more easily into space-constrained EV battery packs.

“Automakers need reliable, scalable partners. With AlkeGel, they now have a superior choice,” says Chad Cannan, Alkegen’s chief technology officer. “AlkeGel has proven to be significantly less dusty than traditional aerogel insulations—making it easier to convert, safer to handle, and more adaptable to complex part geometries.”

With the addition of aerogels, Alkegen builds on its leadership in cell spacer technology to offer a full insulation portfolio—including wraps and thermal barriers—giving EV  manufacturers the flexibility to match material to application.

“The EV industry has been waiting for a credible second source of battery fire protection aerogel insulation in North America,” says Marty Melhorn, president, Battery Pack and Advanced Mobility. “AlkeGel is here. We’re manufacturing at scale—and we’re just getting started.”

Ahlstrom Launches AGM Battery Separator Platform: Ahlstrom announced the launch of a new Absorbent Glass Mat (AGM) battery separator platform, manufactured at a state-of-the-art facility in Turin, Italy. It reinforces Ahlstrom’s position as a trusted partner to battery manufacturers, delivering high-performance, customizable AGM separator solutions for the growing global demand for reliable and efficient energy storage solutions.

As the demand for high-performance energy storage solutions accelerates, AGM lead acid batteries continue to be a cornerstone of high-performance power solutions. They enable rapid charge and discharge cycles across automotive, renewable energy, telecommunications and industrial power backup applications. AGM separators—essential to battery safety, efficiency and longevity—are evolving to meet the industry’s growing need for higher energy efficiency, durability, and sustainability.

Next-generation AGM separators deliver unmatched product uniformity, optimized fiber dispersion, and superior electrolyte retention, which ensure low electrical resistance and enhanced charge acceptance for maximized battery efficiency and lifespan. 
The new flexible platform allows customization from 100% micro glass to advanced micro glass-synthetic fiber blends, which enables battery manufacturers to tailor separator properties to specific battery needs.

“Our investment in the Turin plant underscores Ahlstrom’s commitment to delivering innovative and sustainable solutions for the evolving energy storage market,” says Marcus Ulrich, head of Sales, Energy Storage. “With the new AGM battery separator platform, we are setting new industry benchmark and offering unparalleled quality, efficiency, and durability to battery manufacturers worldwide.”