Collaborative Endeavor by AZL Initiated for Flame Resistance Evaluations in Electric Vehicle Battery Housings
Aachen's New Project Aims to Improve Fire Safety in Electric Vehicles
AZL Aachen, a leading research institution, has launched a new project titled "Thermal Runaway Testing for Battery Casings – Benchmarking Systems for High-Gradient Heating and Hot Particle Blasting." The project, which kicks off on July 15, 2025, aims to establish a realistic and reproducible fire testing environment to evaluate materials used in electric vehicle (EV) battery housings under conditions simulating thermal runaway events in modern lithium-based batteries such as lithium iron phosphate (LFP) and nickel manganese cobalt (NMC).
The project's key features include the development of a new test bench that combines high-gradient flame exposure with controlled hot particle impact to mimic thermal runaway conditions. This test bench will be used for systematic benchmarking of different materials' thermal resistance and mechanical integrity under tailored test profiles that reflect application-specific stress scenarios.
Detailed test documentation, including videos and thermal data, will be provided for the resulting matrix. This matrix will support materials development, qualification, and supplier evaluation, offering both strategic and technical value.
Companies involved in the project can access final benchmarking results, contribute their own material configurations for testing, and pool resources to validate their fire safety solutions against leading alternatives in the market. Previous collaborations by AZL have involved a consortium of over 24 industry players, including automotive OEMs such as Audi and BMW, tier suppliers, and material producers. Similar engagement is expected in this current project, reflecting involvement across automotive and potentially aerospace sectors where safe battery storage systems are critical.
The project's outcomes focus on providing a benchmarking platform that compares over 50 different materials tested in terms of flame temperature survival, tensile load endurance, failure points, weight, and cost per area. This data will guide the development of safer, thermally resilient, and mechanically robust battery casing materials, ultimately enhancing fire safety testing standards tailored for EV battery casings to improve the overall safety and reliability of electric vehicles and related applications.
Companies interested in joining the project are encouraged to request detailed project information or arrange an individual consultation meeting. AZL Aachen GmbH has more than ten years of experience managing collaborative industry projects, ensuring a well-structured and productive collaboration for all participants.
In the scope of enhancing EV battery safety, the new project at AZL Aachen establishes a collaboration between industry players, including automotive OEMs like Audi and BMW, to develop a test bench for materials used in electric vehicle battery housings. This technology-driven endeavor aims to provide a benchmarking platform, evaluating over 50 materials based on flame temperature survival, tensile load endurance, and cost efficiency, which is vital for the advancement of the finance sector and transportation industry.
