Collaborative Initiative by AZL on Fire Safety Assessments for Electric Vehicle Battery Housings Commences
The Automotive Research Centre (AZL) in Aachen, Germany, has announced the launch of a new collaborative project aimed at developing and benchmarking fire safety test systems for materials used in electric vehicle (EV) battery housings. The project, titled "Thermal Runaway Testing for Battery Casings - Benchmarking Systems for High-Gradient Heating and Hot Particle Blasting," was officially unveiled on July 15, 2025.
The initiative, which runs for approximately 9 months, seeks to create a realistic and reproducible fire-testing environment for structural and functional materials used in EV battery casings. It aims to evaluate the behavior of various materials, including steel, aluminum, and composites, under thermal runaway conditions, a critical fire hazard scenario in EV batteries.
The project's setup enables systematic benchmarking of materials under stress conditions reflecting actual applications in automotive and other segments like aerospace. Participating companies will have access to the final benchmarking results and can contribute material configurations for testing as part of the project.
AZL's team of experts has developed an application-relevant instrumented test method for testing materials at different flame temperatures and measuring material strength under fire load. The testing methods include benchmarking systems for high-gradient heating and hot particle blasting, simulating thermal runaway events and fire exposure in modern cell technologies such as LFP and NMC.
With more than ten years of experience managing collaborative industry projects, AZL brings expertise in composite-based battery casing design and multifaceted production techniques for multi-material systems. The project is part of broader efforts to address thermal management and fire protection challenges in electromobility, with increasing importance due to rising demand for high-performance, lightweight, and modular battery components.
Detailed test documentation, including videos and thermal data, will be provided for each material tested. Companies interested in joining the project are encouraged to request detailed project information or arrange an individual consultation meeting. For further specific inquiries or participation, AZL recommends contacting Philipp Fröhlig, Head of Industrial Services.
The resulting matrix supports materials development, qualification, and supplier evaluation, offering both strategic and technical value. By pooling resources, validating their own solutions, and gaining insight into leading alternatives in the market, participating companies can contribute to the advancement of fire safety testing protocols for EV battery casings, promoting sustainability and safety in the electromobility industry.
- The project, initiated in collaboration with industries such as automotive, aerospace, and technology, seeks to benchmark materials used in electric vehicle battery casings to ensure safety, particularly addressing thermal runaway conditions.
- This industry-wide collaboration, involving finance sectors for funding and resource pooling, aims to advance fire safety test systems for electric vehicle battery housings, ultimately fostering sustainability and safety in the transportation sector.
