The materials crisis facing EV battery manufacturers
Conventional battery materials are being pushed beyond their limits. This whitepaper reveals how advanced engineering plastics and polyurethane systems are solving the critical thermal, electrical, and manufacturing challenges defining competitive advantage in EV battery production.
The next generation of EVs will depend on smarter material choices as much as better batteries. Manufacturers that solve the safety and performance challenges simultaneously will move faster and stay competitive. Those that don’t, risk delays, redesigns, or failing to meet new regulations.
China's GB 38031-2025 regulatory standard just raised the bar dramatically. Battery thermal incidents now require two-hour containment with zero fire, zero harmful smoke, and zero explosion - a 2400% jump from the previous requirement. For manufacturers using high-energy cells, meeting this standard while maintaining production efficiency is essential to being competitive in key global markets.
The challenge extends beyond thermal safety. Materials must also meet all of the below requirements:
- Strong thermal protection
- Reliable electrical insulation
- Flame resistance
- Clear safety identification colours
- Fast manufacturing speeds
This whitepaper explores the materials capable of solving these problems, and how leading EV manufacturers are already using them.
BASF's comprehensive portfolio of engineering plastics, and polyurethane systems are delivering measurable results: 15-30% cycle time reduction, thermal protection to 1,350°C, 20-50% weight savings versus metal alternatives, and validated compliance with GB 38031 and UL standards.
