Aerogels show promise in electric vehicle battery safety

Aerogels are being investigated as thermal and fire protection materials for electric vehicle batteries, according to a report by IDTechEx.

The report, titled Aerogels 2025–2035: Technology, Market, Forecasts, outlines the projected use of aerogels across electric vehicles and other sectors over the next decade.

IDTechEx said aerogels are emerging due to their low density, low thermal conductivity and insulation capabilities, with silica-based and silica composite materials currently dominating the market.

NASA originally developed aerogels for aerospace missions such as Stardust and Rover. Since 2020, the material has been tested for thermal barriers and fire protection in the automotive sector.

The report attributed the increased interest in aerogels to the rising number of electric vehicles globally and a corresponding demand for fire protection materials.

Composition and challenges of aerogel integration

According to IDTechEx, aerogels are solid materials composed of 90 to 95 percent air and derived from silica, silica composites or organic materials.

Silica composite aerogels are the most widely used, followed by silica aerogels in powder or granule form. Polymer-based aerogels are being developed for aerospace and battery light-weighting.

These polymer aerogels are up to three times lighter than silica but have lower operating temperatures and higher costs. Material choice depends on industrial application, operational temperature and handling constraints.

The report noted that silica composite aerogels may generate dust during handling, which could impact their performance.

Handling difficulties and the need for encapsulation are cited as limiting factors to wider adoption.

IDTechEx also stated that aerogels are more expensive than other materials, which continues to be a barrier to market entry.

Aerogels compared to other fire protection materials

IDTechEx explained that aerogels are used between cell-level and pack-level protection in battery systems.

Compared to foams and ceramics, aerogels have lower thermal conductivity and density, making them suitable for insulation and fire resistance.

Silica-based aerogels offer higher operating temperatures than polymer aerogels, which is critical for fire protection applications.

However, the report warned that silica composites require careful handling due to dust production.

To improve performance, manufacturers are developing composite aerogels with porous polymer matrices, making them more compressible and better suited to battery expansion and contraction cycles.

These solutions aim to limit the spread of thermal runaway events in battery systems.

Thermal runaway concerns drive new solutions

In its report Fire Protection Materials for EV Batteries 2025–2035: Markets, Trends, and Forecasts, IDTechEx highlighted that growth in electric vehicle sales has increased attention on thermal runaway prevention.

The issue of thermal runaway – the rapid self-heating of batteries leading to fire or explosion – is a key risk area for fire safety professionals.

Aerogels are one of several materials being explored to prevent thermal events or slow their propagation.

The report also referenced a broader analysis of electric transport markets in Electric Vehicles: Land, Sea, and Air 2025–2045.

This analysis forecasts long-term uptake of electric cars, buses, trains, trucks and two-wheelers, reinforcing the importance of safe battery materials.

Regulatory approaches vary by region

IDTechEx reported that regulatory approaches to thermal events differ worldwide.

China was the first country to mandate a 5-minute warning period between the onset of thermal runaway and the appearance of fire or smoke.

In April 2025, Chinese authorities announced plans for a stricter measure, requiring batteries to resist fire or explosion for 2 hours after the initial event.

The regulation is expected to take effect in July 2026.

In other regions, regulation is less advanced and often focuses on alternative safety strategies such as gas management.

The report noted that as regulations evolve, demand for reliable fire-resistant materials such as aerogels is expected to grow.

Aerogels fire protection role in EV batteries: Summary

IDTechEx has reported that aerogels are being explored as fire protection materials for EV batteries.

The material offers low thermal conductivity and density, making it suitable for use as a thermal barrier.

NASA developed aerogels for aerospace applications.

Since 2020, they have been trialled in electric vehicle safety systems.

The most common types are silica composites and powder-form silica aerogels.

Polymer-based aerogels are emerging but are costlier and have lower operating temperatures.

Aerogels are more expensive and require encapsulation.

Handling challenges and dust generation remain technical issues.

Compared to foams and ceramics, aerogels have stronger insulation properties.

Composite variants with polymer matrices are being developed for battery cycling resilience.

IDTechEx identified thermal runaway as a core risk in battery design.

Electric vehicle growth is increasing the need for fire protection materials.

China has introduced a 2-hour post-event fire resistance regulation.

Other countries may follow with their own standards.

Aerogels are expected to see increasing use if handling and cost barriers can be addressed.