Thermal runaway and system safety are critical topics when it comes to using lithium ion (Li-ion) batteries in electric vehicles. A key focus for the EV industry is the need to apply fire protection materials to prevent or delay thermal runaway propagating between cells and eventually outside of the battery pack. With growing regulatory momentum and safety standards, this article from IDTechEx looks at the outlook for fire protection materials market.
Thermal runaway and system safety are critical topics when it comes to using lithium-ion (Li-ion) batteries in electric vehicles. While there are various methods for reducing the likelihood of thermal runaway, such as effective thermal management and active cooling solutions, quality control, and battery management systems, no method is 100% effective. Fire protection materials play a major role, serving as a passive method to prevent or mitigate the propagation of thermal runaway. Within the EV batteries market, IDTechEx forecasts that fire protection materials will grow at a CAGR of 13% over the next decade to exceed US$10 billion by 2037.
Thermal Runaway and Fire Safety Standards
There are several causes of thermal runaway, including overcharging, overheating, internal short circuits, and mechanical damage. For example, a manufacturing defect in any type of cell could cause an internal short circuit, that may lead to thermal runaway. Additionally, higher energy density cells generally exhibit higher temperatures during thermal runaway.
With EVs becoming an increasingly large part of the fleet, their safety becomes ever more important. Although EV fires are statistically less common than fires involving internal combustion engines vehicles, safety cannot be overlooked at any rate of occurrence. As such, regulators are increasingly introducing stricter fire safety requirements for electric vehicles.
For example, China was an early adopter of thermal runaway specific regulations, with a need to prevent fire or smoke exiting the battery pack for 5 minutes after the event occurs, among other requirements. China's GB 38031-2025 mandated from July 2026 pushed forward with even stricter requirements for no fire or explosion under test conditions (i.e. 2 hours). Elsewhere, Europe and US mainly look to UC ECE regulations, though US's FMVSS 305a has taken a less stringent standard for safety.
Nonetheless, China's GB 38031-2025 signals that the 5-minute escape time is unlikely to be sufficient for future regulations and more effective thermal runaway propagation measures will be necessary. Speaking to players, IDTechEx understands that several OEMs have started to target longer escape times in order to pre-empt future regulations and improve overall safety.
Snapshot of Fire Protection Materials Market for EV Batteries
A key focus for the EV industry is the need to apply fire protection materials to prevent or delay thermal runaway propagating between cells and eventually outside of the battery pack. These materials can be applied at the cell-level and at the pack-level. Materials applied at the cell-level are applied between or around the cells to help prevent propagation of thermal runaway from a specific cell. These typically include encapsulating foams, aerogels, compression pads (with additives), mica, and a few others.
On the other hand, pack-level protection concerns materials that are used within the pack or as a coating of the pack but not directly between cells. These are generally designed to stop fire propagating between modules or outside of the pack. Typical materials in this application would be ceramic blankets (plus other non-wovens), aerogels, mica, powder coatings, intumescent coatings, and others.
Comparison of market size of fire protection materials in 2025 and projected growth over the next decade. Source: IDTechEx
IDTechEx's report on "Fire Protection Materials for EV 2027-2037: Markets, Trends, and Forecasts" looks at the different fire protection materials used at the cell-level and pack-level across vehicle types (cars, trucks, 2 and 3 wheelers, microcars, etc.). According to IDTechEx research, at present, materials with large market sizes include the likes of aerogels, mica, foam, together amassing a market revenue of over US$1.6 billion in 2025. On the other hand, although intumescent coatings, compression pads (with fire protection) and polymers captured a smaller share of the market size in 2025, IDTechEx forecasts strong growth for these materials over the next decade. 10-year market forecasts for market size and demand for materials at the cell- and pack-levels are available within the report.
Outlook
With evolving regulations, IDTechEx's market forecasts show a greater adoption of fire protection materials. However, this must be paired with trends around battery development that can often reduce material use per vehicle. The variety of battery designs and material solutions presents a large opportunity across several markets and suppliers.
IDTechEx's report on Fire Protection Materials for Electric Vehicle Batteries analyzes trends in battery design, safety regulations, and how these will impact fire protection materials, with detailed benchmarks of fire protection materials. Using IDTechEx's material database of over 150 materials from 72 suppliers, the materials covered include ceramic blankets/sheets (and other non-wovens), mica, aerogels, coatings (intumescent and other), encapsulants, encapsulating foams, compression pads, phase change materials, polymers, and several other materials. Each of these have more or less suitable applications, and the major categories are benchmarked in the report in terms of thermal conductivity, density, cost, and cost in the required application volume. 10-year market forecasts are included by material and vehicle category.
For more information on this report, including downloadable sample pages, please visit www.IDTechEx.com/FPM, or for the full portfolio of research related to thermal management, advanced materials, batteries and EVs available from IDTechEx, see www.IDTechEx.com.
