The handsheets of an alkaline battery separator were made of polypropylene (PP) fibers and polyethylene/polypropylene bicomponent sheath-core structure (EP) fibers in the wet-laid process followed by a hot pressing treatment. The effects of the process parameters in making the separator handsheets on the formation and the resultant tensile strength, maximum pore size, porosity, and alkali resistance were investigated. The results showed that a favorable formation could be obtained at the EP fibers addition level of not less than 20%. In addition, the tensile strength, maximum pore site, porosity, and alkali resistance of the separator handsheets made of 60% PP fibers and 40% EP fibers could meet the needs required in QB/T 4173 (2011), under the conditions of 1.5% PEO and 4.0% PVA additions (on oven-dry fibers), the hot-pressing pressure of 0.5 MPa, and the hot-pressing temperature of 135 C-omicron for 90 s.