Among these are epoxy resins – durable, high-performance materials that are literally built into the physical fabric of the energy transition. Used extensively in transformers, circuit boards, insulators, generators, battery enclosures, and high-voltage transmission components, epoxy systems ensure the safety, reliability, and performance of an increasingly stressed grid. Without them, much of Europe’s electrification effort would stall at the infrastructure level.
Electrical infrastructure under pressure
The EU is now facing the limitations of its existing electricity infrastructure. According to the Agency for the Cooperation of Energy Regulators (ACER), one-third of grid investments over the next decade must be allocated to modernising ageing equipment. High-voltage substations, power converters, smart grid electronics and cross-border interconnectors are all being expanded – and each of these systems uses epoxy materials for electrical insulation, chemical resistance, and mechanical integrity.
Epoxies are not simply optional extras. Epoxies are used in key electrical parts like bushings, cast-resin transformers, and modern composite insulators. These newer components are now chosen more often than the old porcelain ones because they are lighter, stronger, and handle electricity better. These are not boutique products; they are critical to the grid. Their performance directly affects service lifetime, system losses, and fire safety in high-demand conditions. As new renewable connections push existing infrastructure to its limits, these properties are not luxuries – they are fundamental requirements.
Electrification beyond the grid
The electrification of transport and industry also relies on epoxy chemistry. In electric vehicles, epoxy formulations are used to encapsulate battery modules and protect power electronics. Lightweight composites based on epoxy resins enable the production of chassis and body components that reduce the overall weight of vehicles, thereby extending range and improving their efficiency. The same applies to electrified rail, aircraft systems, and marine propulsion, where weight-to-strength ratios are critical.
Similarly, industrial electrification, including high-voltage motors and power electronics for manufacturing, likewise depends on epoxy-based insulation systems. These materials ensure stable performance under high thermal and electrical loads. Without them, there would be an increase in equipment downtime and efficiency losses, driving up operating costs across electrified sectors.
A role acknowledged, but not yet reflected
Recent EU policy recognises the urgency of electrification. The 2024 Affordable Energy Package emphasises the importance of faster permitting processes and robust supply chains to reduce energy costs for consumers and businesses. The Grids Package calls for improved visibility into grid component requirements and investment bottlenecks. However, attention is still lacking with regard to the materials that underpin these components.
There is a risk that broad regulatory measures targeting chemical groups may unintentionally restrict access to substances that are essential for electrification infrastructure. Several key ingredients in epoxy systems – including advanced hardeners and additives – are under review in ongoing REACH evaluations. The intention to protect health and the environment is commendable. However, a one-size-fits-all approach, or a lack of transitional planning, could hinder the deployment of the very technologies that the EU is simultaneously trying to accelerate.
A pragmatic way forward
We should ensure that critical applications involving materials, such as those found throughout the electrification chain, are considered in risk assessments and transition planning. The epoxy value chain is already investing in more sustainable formulations, including mass-balance bio-based inputs and circular chemistry approaches. However, material innovation requires time, testing, and collaboration.
A more integrated approach between chemicals policy and energy-industrial planning would support this transition. After all, electrification is not just a target, it’s a vast complex system. And like any system, its success depends on components that are often overlooked.
Originally published on Euractiv on November 20th 2025.