Axalta coatings for more battery safety in electric vehicles
Axalta presented two innovative products at the Battery Show North America 2025 to increase battery safety in electric vehicles. The powder coatings are designed to delay the spread of fires.
Axalta has introduced two new powder coatings for electric mobility applications. The products Alesta e-Pro FG Black and Alesta e-Pro Dielectric Gray have been specially developed for use in battery packs of electric vehicles. The aim is to improve thermal stability and electrical insulation performance in high-voltage systems. Electric vehicles are statistically considered to be less susceptible to fire than vehicles with combustion engines. Nevertheless, there are still safety concerns among the public, particularly in connection with so-called "thermal runaway" events. Here, the overheating of a single battery cell can trigger a chain reaction that leads to high temperatures, smoke development and structural damage.
Powder coating delays battery fires
The new Alesta e-Pro FG Black coating is designed for extreme heat resistance and is intended to delay the spread of fires in the event of a thermal reaction. The product withstands temperatures of up to 1200 °C, shows no smoke development and offers additional corrosion protection. Alesta e-Pro Dielectric Gray is designed to provide reliable electrical insulation in high-voltage environments. The epoxy-based coatings are characterized by uniform edge coverage, high flexibility and high dielectric strength. They pass various tests, including UL 94 V0 and IEC 60243-1, and both coatings have undergone extensive testing to confirm their resistance to heat and electrical voltage. In combination with validated battery systems from OEMs, they can help increase safety and reliability.
Axalta coatings for electric vehicle batteries
According to Axalta, the development is aimed at global automotive manufacturers and suppliers that produce batteries for electric vehicles and energy storage systems. With an expected market volume of over 20 million electric vehicles in 2025, the technology is expected to contribute to the further acceptance of electric mobility. Dr. Robert Roop, Axalta's Chief Technology Officer, emphasized that the new coatings are an expression of the company's continuous research and development work to provide solutions for the requirements of future mobility concepts.
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