Electric vehicle safety outlook predicts five-fold growth in EV fire coatings
Iain Hoey
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Forecast raises new supply chain questions around electric vehicle safety
Future Market Insights said a newly released report values the PFAS-Free EV Battery Fire-Protection Coatings market at USD 1.6 billion in 2026, rising to USD 7.7 billion by 2036.
The report described a compound annual growth rate of 17.6% across the forecast period.
Future Market Insights linked the market shift to efforts to prevent battery fires described as thermal runaway and to remove per- and polyfluoroalkyl substances (PFAS) from coating chemistries.
Electric vehicle safety drivers cited by report
Future Market Insights said some fire-resistant coatings have historically relied on PFAS due to heat tolerance.
The report said tightening regulations in North America and Europe and growing demand for cleaner manufacturing are pushing original equipment manufacturers to move to PFAS-free alternatives.
Future Market Insights framed the change as affecting automotive supply chains as electric vehicle production volumes increase.
Coating types and reported market shares
Future Market Insights said liquid coatings hold a 40% market share because they can be applied across complex battery pack geometries.
The report said intumescent coatings account for 30% of the market.
Future Market Insights said intumescent coatings expand under heat to form a char barrier intended to insulate the battery and create time for passengers.
Regional growth rates highlighted by Future Market Insights
Future Market Insights said China leads forecast growth at 12% compound annual growth, which it linked to domestic electric vehicle production volumes.
The report said India follows at 11%, which it linked to government incentives including the FAME scheme.
Future Market Insights said the US is forecast at 10% and the UK at 9%, which it linked to environmental regulations and a shift toward sustainable transport.
What this means for electric vehicle safety engineering
Fire engineering consultants and mechanical and electrical engineers working on vehicle systems may use the forecast figures and coating-type shares to benchmark where suppliers are concentrating product development.
Procurement officers and equipment specifiers supporting electric vehicle manufacturing may track the reported shift away from PFAS-based chemistries when reviewing material specifications for battery pack fire protection.
Standards and certification bodies may also watch the market direction described in the report, as it frames PFAS-free coatings and thermal runaway mitigation as linked requirements in future battery designs.
Emergency and disaster response managers may note the report’s focus on thermal runaway prevention as a driver behind new protective materials entering the vehicle fleet over the 2026 to 2036 period.