Green New Energy Materials, INC. (GNEM)
Engineering Battery Separator Solutions

Battery separators are becoming an increasingly critical component of modern cell manufacturing. As battery makers push toward thinner separators and higher energy density while meeting stringent requirements for safety and durability.

The technical challenge does not end with developing a separator that performs in the laboratory, but lies in producing that separator consistently, at scale, and in a way that fits the customer’s manufacturing process and cost requirements.

Green New Energy Materials, INC. (GNEM) operates at this critical intersection, developing battery separator solutions designed to help manufacturers balance performance, safety, consistency, and commercial viability.

The separator is a simple but essential component within a lithium-ion battery – often referred to by GNEM as the unsung hero in battery performance. It separates the anode and cathode while enabling ion movement, directly influencing battery efficiency, safety, and durability. As cell designs become more advanced, separators must evolve beyond basic specifications. They must be thin enough to support energy density improvements while maintaining mechanical strength, thermal stability, and the ability to perform consistently across demanding manufacturing environments. GNEM’s approach centers on solving this broader production challenge.

Building Domestic Manufacturing Strength

GNEM describes itself as a U.S.-based high-volume battery separator manufacturer focused on resilient manufacturing. The company entered the domestic market to address a significant supply chain gap as battery investments accelerated across the United States. While substantial funding flowed into battery development, domestic separator manufacturing capacity remained limited. GNEM’s parent company invested in establishing U.S. separator production capabilities to support the transition toward a stronger local battery ecosystem.

At the heart of GNEM’s manufacturing strategy is its North Carolina facility, representing a $140 million investment and a 534,000-square-foot operation supporting more than 500 jobs upon project completion. The facility provides advanced manufacturing capabilities, including a double-sided U-style coating process that enables more efficient production of coated battery separator films. This approach allows GNEM to increase manufacturing scale and improve efficiency while supporting the needs of customers seeking reliable domestic supply.

The company’s manufacturing foundation combines advanced equipment with technical expertise. Producing separators for modern batteries requires more than machinery; it requires process knowledge, skilled technicians, and the ability to achieve high yields while maintaining cost competitiveness. GNEM positions its capabilities around delivering consistent quality and supporting the future growth of battery manufacturing supply chains.

Engineering Thin Separators without Compromise

One of the industry’s most important development trends is the move toward ultra-thin separators. GNEM works with separators as thin as five micrometers, a level of engineering that creates opportunities for improved energy density but introduces significant manufacturing challenges. A thinner separator must still maintain the strength required for production processes, safety requirements, and long-term battery performance.

GNEM does not approach separator development by focusing on thickness alone. The company collaborates with battery manufacturers to understand their production capabilities and match separator designs with specific cell requirements. Emery Brown, Ph.D., Marketing Director at GNEM, explains, “Really thin separators can do a lot for the energy density, but it’s our job to ensure their compatibility with customers manufacturing process. We have to get both thickness and mechanical strength optimized to fit both their manufacturing capabilities and their performance requirements for the cell.”

This manufacturing-focused perspective recognizes that a separator’s value depends on how effectively it performs inside a customer’s process. Parameters such as mechanical and tensile strength, porosity, Gurley number, safety characteristics, base film and coating thickness, and compatibility with different battery formats must work together. GNEM’s experience across global battery markets allows it to support requirements for applications where safety and reliability are especially critical, including electric vehicles and energy storage systems.

Customization Designed for Commercial Success

GNEM’s differentiation comes from its collaborative approach to product development. Rather than treating customization as simply creating a separator around every requested specification, the company works with customers to identify solutions that can be manufactured efficiently and economically.

The company maintains a portfolio of more than 3,000 separator configurations covering different coatings, thicknesses, and porosity levels. Through close collaboration between GNEM’s technical teams and customer engineering teams, the company evaluates suitable products for specific battery systems. Qualification is a detailed process involving sampling and validation, often requiring six months to a year before large-scale orders are placed.

This process considers the complete battery manufacturing environment. GNEM evaluates factors such as winding speed, cell format, and assembly methods, including cylindrical, pouch, and prismatic designs. These details influence separator selection because each manufacturing process places different demands on separator performance and strength.

The company also brings an advisory role to customer relationships. GNEM helps customers understand available options and guides them toward solutions that meet technical requirements without creating unnecessary complexity or excessive cost. A highly specialized separator may satisfy performance goals but become difficult to manufacture at commercial volumes. GNEM focuses on finding the right balance between engineering requirements, production realities, and business outcomes.

Supporting Diverse Battery Applications

Battery separator requirements vary significantly depending on the application. Electric vehicle manufacturers may prioritize different combinations of safety, charging speed, range, and cost depending on their vehicle designs. Energy storage systems place greater emphasis on safety, longevity, and return on investment because of their large-scale deployment and operational expectations.

GNEM’s broad product portfolio and ability to collaborate across applications provide flexibility in addressing these different requirements. The company’s advantage comes from matching separator technology with each customer’s manufacturing capabilities while delivering solutions that remain commercially practical.

The company’s broader experience includes solutions developed for complex battery challenges. One example involved supporting an electric vehicle manufacturer seeking improved charging performance. The collaboration contributed to the development of a nanofiber coating series that improved porosity, wetting, and ion mobility. Another example involved a customer with a unique cell design experiencing winding issues and separator damage. A specialized edge bonding solution helped integrate the separator into the manufacturing process. These examples demonstrate GNEM’s focus on solving production challenges, not merely adjusting specifications.

Positioned for the Next Phase of Battery Growth

As the battery market evolves, GNEM continues to expand its capabilities alongside changing industry demands. The company sees continued opportunities in both electric vehicles and energy storage systems, with market dynamics shifting as manufacturers adapt to new priorities. GNEM plans to expand capacity as needed and explore additional research and development capabilities in future phases.

The company’s position is strengthened by its ability to combine global separator expertise with U.S. manufacturing presence. GNEM identifies consistency, quality, and scalable production as critical advantages in a market where battery manufacturers require dependable supply partners.

Battery innovation is often measured by the performance of the finished cell, but manufacturing determines whether that innovation can reach the market. GNEM represents a manufacturing-led approach to separator development, where technology decisions are evaluated through the lens of real-world production. As the industry moves from ambitious battery targets toward commercial-scale execution, separator leadership will depend not only on how advanced a material can become, but on whether it can be produced consistently, safely, and economically.

GNEM’s role in this transition reflects a larger shift in battery manufacturing: transforming technical possibilities into reliable industrial solutions. This commitment defines GNEM’s manufacturing vision.