Powering the Future: How Tape Solutions Are Driving Electrification Across Emerging Markets
From wheels to wings to watts, and everything in between, battery technology is powering the future. What began as a revolution in electric vehicles has rapidly evolved into a sweeping cross-sector transformation, redefining how we store, move, and manage energy.
Advancements in technologies from Lithium-ion to Solid- state batteries are not only driving cleaner transportation but also enabling stationary energy storage systems (BESS) that enhance grid resilience and accelerate the integration of renewables. These same innovations are streamlining industrial logistics with high-efficiency forklift batteries and even lifting us into the skies through the emerging eVTOL (electric vertical takeoff and landing) market.
At the heart of this electrified movement lies the evolution of EV battery technologies, now a cornerstone of global energy innovation. Their expansion far beyond the automotive sector signals a powerful shift: one where energy is no longer simply consumed, but intelligently conserved, stored, and deployed to build a cleaner, more connected world.
To explore how this transformation is unfolding, we spoke with Dr. Fei Wang and Maggie Ezell from the Tape Solutions team. Together, they offer a high-level overview of trends in stationary storage, eVTOL, and forklift applications, and highlight the critical role of advanced materials in enabling next-generation energy systems.
What are the current market projections?
The Battery Energy Storage System (BESS) market is experiencing remarkable growth, driven by the global shift toward cleaner energy and smarter grid infrastructure. According to MarketsandMarkets, the BESS market is projected to expand from $7.8 billion in 2024 to $25.6 billion by 2029, reflecting a robust compound annual growth rate (CAGR) of 26.9%.
This surge is fueled by several key factors: the widespread adoption of renewable energy sources, declining battery costs, and supportive government policies across major regions. Additionally, technological advancements, such as AI-powered predictive maintenance and optimized charging cycles, are significantly improving system efficiency and reliability. As a result, BESS is becoming a cornerstone of the global energy transition, enabling renewable integration, grid stability, and decentralized power solutions.
Among emerging battery chemistries, Lithium Iron Phosphate (LFP) is gaining traction due to its strong safety profile and cost-effectiveness. LFP batteries offer a compelling combination of safety, longevity, and affordability, without relying on rare or geopolitically sensitive materials, making them an increasingly attractive choice for energy storage applications.
What is required for a successful BESS system?
To achieve long-term durability and safety, BESS systems must deliver high energy density, robust thermal management, and cost-efficiency, all while operating reliably under demanding environmental conditions. Within BESS storage systems, there is a prioritization of materials that enhance compression stability, thermal regulation, and fire protection.
Tape Solutions materials can play a vital role in supporting these performance requirements. For instance, compression pads with low compression force deflection (CFD) help maintain consistent pressure on battery cells, extending their lifespan and optimizing loading cycles. Thermal Interface Materials (TIMs) are essential for effective heat dissipation, while fire-blocking barriers such as the Norseal® TRP Series are critical in preventing thermal runaway propagation, especially in high-density lithium-ion systems.
With a portfolio designed to meet the evolving demands of BESS applications, Tape Solutions offers advanced materials including micro-cellular polyurethane foams, thermal gap fillers, sealing gaskets, silicone coated fabrics and expanded PTFE films. These solutions not only enhance energy density and safety but also contribute to reducing system footprint and total cost of ownership.
Backed by deep application expertise, Tape Solutions can help empower customers to build BESS platforms that are safer, smarter, and built to last well into the future.
Mirroring the growth trajectory of the Battery Energy Storage System (BESS) market, the electric Vertical Takeoff and Landing (eVTOL) sector is also experiencing rapid expansion. Both industries rely heavily on high-performance, safe, and scalable battery technologies. Like BESS, eVTOL platforms require lightweight, thermally stable, and energy-dense battery systems to ensure safety, efficiency, and long-term reliability. The overlap in technical requirements, such as thermal management, compression stability, and fire protection, means that innovations in BESS materials can be transferable and beneficial to the eVTOL industry.
According to Precedence Research, the eVTOL aircraft market is projected to grow from $2.14 billion in 2025 to over $170 billion by 2034, representing an extraordinary CAGR of 54.9%. This growth is driven by the rising demand for sustainable urban air mobility, advancements in autonomous flight technologies, and increased investment in infrastructure and regulatory certification. Applications range from air taxis and cargo transport to emergency medical services, all poised to transform how we navigate urban environments and beyond.
To ensure the safety, reliability, and longevity of eVTOL aircraft, manufacturers prioritize advanced battery systems with robust thermal management and cell-level monitoring to prevent overheating and extend battery life. Additional requirements include redundant flight systems, lightweight yet durable materials, and quiet operation to meet the standards of urban mobility. These needs closely align with those in the BESS sector, where high-performance materials, such as thermal barriers, compression pads, and gap fillers can play a critical role in enabling safe and long-lasting energy storage and electric propulsion.
Tape Solutions is uniquely positioned to support these requirements with a specialized portfolio of materials. For example, products like Norseal® PF Series compression pads help maintain optimal cell pressure, while TRP1000 silicone barriers mitigate the risk of thermal runaway. For high-temperature flame resistance, FR1000 Mica Tape can also be a top contender for providing essential protection.
Combined with deep expertise in EV battery systems and fast-charging infrastructure, Tape Solutions enables engineers to design safer, more durable, and efficient eVTOL platforms that meet the rigorous demands of electric aviation.
According to Future Market Insights, the forklift battery market is projected to grow from $5.9 billion in 2025 to $12.3 billion by 2035, with a compound annual growth rate (CAGR) of 7.6%. This growth reflects a broader shift toward electrification, automation, and sustainability in material handling operations.
What is contributing to this growth?
Factors include the rise of e-commerce, the expansion of smart warehouses, and increasingly stringent emissions regulations that favor electric forklifts over internal combustion models.
Another key trend driving this transformation is the growing adoption of lithium-ion batteries, which offer higher energy density, faster charging, and longer lifespans compared to traditional lead-acid batteries.
To ensure long-term reliability and performance, forklift battery systems must deliver optimized thermal management, consistent compression, and robust fire protection, requirements that closely align with those seen in BESS and eVTOL applications. Fast and ultra-fast charging capabilities are becoming increasingly critical, as they reduce downtime and boost operational efficiency. As a result, advanced battery technologies and supporting materials, like those provided by Tape Solutions, can be the missing key for powering the next generation of forklift fleets.
Forklift batteries are critical to the future of material handling and heavy-duty vehicles, which demand robust energy systems capable of delivering high power in short bursts for heavy lifting (fast discharge), while also enduring long operational cycles and harsh environments. With total cost of ownership being a key concern, fast charging is essential to minimize vehicle idle time and maximize productivity. To ensure safety, performance, and longevity, mechanical cushioning and thermal management are vital in battery pack design. Tape Solutions supports this need with specialized cushioning materials, like our polyurethane-based Norseal PF Series, tailored to maintain optimal pressure and durability across diverse conditions. Additionally, our thermal management portfolio helps customers design battery packs that stay cool, safe, and efficient, even under demanding use.
From stationary storage to electric aviation and material handling, the electrification journey is not only accelerating, it’s reshaping how industries approach energy. As the demand for cleaner, more efficient technologies grows, the need for safe, high-performance, and scalable energy solutions becomes increasingly vital.
At Tape Solutions, we’re proud to support this transformation with materials engineered to enhance reliability, safety, and operational efficiency across a wide range of applications.
Our commitment extends beyond electrification. We’re committed to helping shape a future where energy is not only generated and stored more intelligently, but also used more responsibly. Through innovations in thermal management, compression stability, and fire protection, our materials contribute to systems that are built for longevity, operate with greater efficiency, and help support a more sustainable energy ecosystem.
Connect with our Tape Solutions team today to explore how our materials can help you design energy systems that are safer, smarter, and more sustainable.