Functional and electrical insulating coating for high-voltage systems, EV battery systems and stationary energy storage systems
SURFACE IS FUNCTION
BENSELER develops and industrializes high-voltage coating solutions for components that must do more than resist wear or corrosion. In electric vehicles, energy storage systems and demanding industrial applications, coated surfaces become functional safety layers: they provide electrical insulation, corrosion protection, thermal stability and process-reliable performance in series production.
Trust is built on proven experience:
- Automotive supplier experience
- Production-proven coating systems
- Tested, validated and documented
- Developed in Germany for customers in Europe and international projects
What is a high-voltage coating?
What functions does a high-voltage coating provide?
How is electrical insulation verified by HiPot testing?
Which components typically require high-voltage coating?
How do I choose the right high-voltage coating for a battery enclosure?
Does BENSELER support customers during the development phase?
Developed for industrial requirements in Germany and Europe
BENSELER develops high-voltage coating solutions in Germany and aligns them with the requirements of European OEMs, Tier suppliers, energy storage manufacturers and industrial customers.
As a provider of high-voltage coating in Germany and Europe, BENSELER focuses on electrical insulation, corrosion protection, thermal stability and production-ready implementation for safety-relevant components.
Where surface becomes function – applications for high-voltage coating
Functional coatings ensure safety, reliability and reproducibility in high-voltage systems, energy storage systems and industrial applications. They add defined technical properties to the surface: electrical insulation, corrosion protection, thermal stability, media resistance, fire safety support and assembly compatibility.
The requirements vary by application. The principle remains the same: the surface is not just a protective layer. The surface is a functional part of the system.
Electric Mobility (EV)
In electric mobility, high-voltage coating is a safety-relevant part of the EV battery system. Battery trays, battery enclosures, busbars, cooling plates and power electronics components require surfaces that help prevent electrical breakdown, protect against corrosion and remain stable under mechanical and thermal stress.
Benefits of BENSELER high-voltage insulation coating for EV applications:
- Electrical insulation for high-voltage battery systems
- Corrosion protection for battery trays, battery housings and structural components
- Thermal stability under load cycles and temperature changes
- Production-ready coating systems with testing and documentation options
Typical components:
- Battery trays and battery housings
- Battery enclosures and covers
- Cooling systems and cooling plates
- Busbars and conductive rails
- Power electronics components
Components in the field of electromobility
Energy storage systems (ESS)
Stationary energy storage systems operate over long periods and are often exposed to demanding environmental conditions. Coatings for ESS components must provide long-term corrosion protection, electrical safety, media resistance and thermal stability.
Benefits of BENSELER coating solutions for energy storage systems:
- Safety and reliability during continuous operation
- Protection against moisture, condensation, salt, UV radiation and media exposure
- Electrical and thermal stability over the defined service life
- Coating solutions for indoor, outdoor and container-based energy storage applications
Typical ESS components:
- Battery modules and battery cabinets
- Battery enclosures and outdoor housings
- Mounting systems and structural components
- Cooling components and interfaces
- Fasteners and functional connection elements
Components in the field of electromobility
Industrial applications
In industrial applications, surfaces frequently have to perform several technical functions at the same time. Functional coating systems can combine corrosion protection, wear resistance, electrical insulation, defined friction behavior and process-reliable surfaces.
Benefits of BENSELER functional coating solutions for industrial applications:
- Wear and corrosion protection for demanding environments
- Electrical insulation and defined surface functions
- Controlled friction coefficients for assembly processes
- Process stability and reproducible quality in series production
Typical components:
- Electrical components
- Machine and structural components
- Fastening elements and connection technology
- Functional interfaces and coated assemblies
Components for industrial applications
Which solution is right for your application?
Functional coating solutions for high-voltage and industrial systems
Technical requirements always originate from the application, not from the coating process alone. BENSELER combines coating technologies into functional system solutions that address electrical insulation, corrosion protection, thermal stability, assembly reliability and fire safety requirements.
When environmental exposure matters: corrosion protection
When electrical safety is critical: electrical insulation coating
When thermal stress must be controlled: thermal stability and temperature management
When assembly processes must be reproducible: assembly reliability
When additional safety is required: fire safety and thermal runaway mitigation
Do you want to know which standards and tests are relevant for your application?
BENSELER supports customers in evaluating battery trays, battery enclosures, cooling systems, busbars and function-critical interfaces. Together, we define a testing and validation plan that fits the application, component geometry and safety requirements.
Coating technologies for high-voltage requirements:
From electric mobility to energy storage and industrial systems
The right coating technology depends on the application, not on the process alone. Depending on material, geometry, voltage level and functional targets, BENSELER combines different coating technologies into a stable, production-ready system solution.
The coating process is not the goal. It is the means to achieve electrical insulation, corrosion protection, thermal stability, assembly reliability and manufacturability.
Overview of core technologies
Cathodic electrocoating / e-coat (KTL)
Electrostatic Powder Coating (EPS)
Liquid coating / Wet paint coating
Zinc flake coating
Which technology meets which requirement?
Electrical Insulation
Thermal resistance
Fire safety & thermal runaway mitigation
Corrosion protection
BENSELER combines coating technologies according to component, material, functional requirement, validation logic and series production process.
Trust through proven quality, series production capability and validated coating solutions
High-voltage coatings must prove their function not only in the laboratory, but also in industrial series production. BENSELER develops, validates and produces coating solutions for electric mobility, energy storage systems and industrial applications based on established testing methods, relevant standards and many years of experience as an automotive supplier.
The goal is technically robust, cost-effective and production-ready coating solutions, including testing, documentation and traceability.
Proven in automotive applications and transferable to ESS and industrial markets
Production readiness as the benchmark
Production capacities and series production facilities in the BENSELER network
Standards, test frameworks, and customer-specific specifications
Manual HV testing of components during the project phase.
HiPot series testing system, individually tailored to customer projects.
Testing Procedures and Validation, including traceability
Verification of a functional high-voltage coating is based on coordinated testing procedures, structured validation and in-process quality controls. The validation concept is tailored to the component, coating system and series production process.
Typical test modules
Traceability in series production: DMC + database
Would you like to know which certifications are relevant for your high-voltage application?
We support you in evaluating battery trays, battery housings, cooling systems, busbars, and function-critical interfaces, so your testing and validation plan fits your application.
Contact – Your direct point of contact for high-voltage coating and functional surfaces
Functional high-voltage coatings result from the interaction between application, component design, coating technology and testing methodology. Direct technical communication is therefore essential. BENSELER evaluates requirements, clarifies constraints and works with customers to define a solution that is technically robust and transferable to series production.
Response usually within 24 to 48 hours
Your project, our joint solution
Do you already have a specific requirement, drawing or component? Or would you like to have an application evaluated? The earlier BENSELER is involved, the more precisely component design, function, coating technology and validation concept can be aligned.
Typical topics in the initial consultation:
- Component and geometry: contact surfaces, edges, recesses, masking and sealing zones
- Functional requirements: electrical insulation, corrosion protection, thermal performance, assembly behavior
- Testing and validation logic: HiPot testing, corrosion testing, temperature cycling, media resistance
- Production context: quantities, SOP timing, process window, traceability and documentation
Helpful for a quick initial assessment:
- Drawing, CAD file, PDF or STEP data
- Material and surface condition
- Operating environment and media exposure
- Target functions: insulation, corrosion protection, thermal stability, assembly reliability
- Quantity, prototype timing and SOP schedule
Any questions?
On our FAQ page, you’ll find all frequently asked questions regarding high-voltage coating, ranging from technical details on HiPot testing and fire safety requirements to mass production processes and APQP standards.