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U.S. Invests $670M in Cutting-Edge EV Fire Prevention Technology

Mike Colagrossi

A company specializing in fire-suppressing materials for EV batteries, Aspen Aerogels, just secured a $670.6 million loan commitment from the Department of Energy. 

The loan, pending final approval, will support the completion of Aspen Aerogels’ new manufacturing plant in Georgia. This move aligns with the DOE’s efforts to strengthen domestic EV supply chains and enhance fire-resistant technology as the demand for safer battery solutions grows.

Sustainable Tech: These materials act as thermal barriers, which can be layered inside an EV battery to slow or prevent the spread of heat and fires. 

As electric vehicles (EVs) become more common, concerns about lithium-ion battery fires have grown. Although gas-powered cars catch fire more frequently, EV battery fires pose unique challenges due to thermal runaway, a process where a damaged or overheated battery cell triggers a chain reaction, potentially leading to fires or explosions. 

These incidents are hard to extinguish, with the risk of re-ignition even after initial control, making them particularly dangerous for first responders​.

MIT Technology Review notes that these barriers are incredibly lightweight, meaning they don’t significantly affect the battery’s energy density or overall weight, unlike traditional aerogels.

  • The barriers are between one and four millimeters thick and can be stacked between battery cells. 
  • According to CEO Don Young, the cost of installation ranges from $300 to $1,000 per EV.

The company is making waves in the EV and sustainability space, with multi-year contracts already in place with major automakers like General Motors, Toyota, and Audi. The company’s materials are in high demand—not just for EVs, but for everything from NASA’s space programs to Formula One cars. Aspen aims to produce enough materials to power over two million EVs annually by 2027.

With its Rhode Island plant already at capacity, the new Georgia facility will be fully dedicated to making next-generation materials for EV batteries, working to drive forward a more sustainable automotive future.

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