Axalta Coating Systems, a global leader in coatings technology, has unveiled two new innovations aimed at improving electric vehicle (EV) battery safety.
The company introduced the products, Alesta e-PRO FG Black and Alesta e-PRO Dielectric Gray, at The Battery Show North America.
The new launch underscores Axalta’s commitment to advancing energy storage safety and performance across the automotive industry.
The new coatings are engineered to deliver exceptional heat protection and electrical insulation, addressing safety challenges associated with thermal runaway events in EV batteries.
Thermal runaway, while rare, occurs when an overheated cell triggers a chain reaction leading to extreme heat, fire, or structural failure.
Dr. Robert Roop, Senior Vice President and Chief Technology Officer at Axalta, said the company’s latest innovations highlight how coatings can play a critical role in supporting safer and more reliable electric vehicles.
Roop said, “While electric vehicles are statistically far less likely to catch fire than gasoline-powered vehicles, high-profile incidents and misinformation continue to impact public perception.”
“These breakthrough products demonstrate the amazing power of coatings to rise to new challenges and reflect Axalta’s history of innovating products that impact the world for the better,” he added.
Alesta e-PRO FG Black is designed for extreme heat protection, offering thermal stability and secondary fire resistance in battery systems. It maintains integrity under temperatures ranging from 600°C to 1200°C, emits zero smoke, and provides strong corrosion resistance, delaying fire propagation during thermal events.
Alesta e-PRO Dielectric Gray focuses on superior electrical insulation for high-voltage environments, such as EV battery packs and energy storage systems. It provides consistent insulation across complex geometries, excellent flexibility, high lap shear strength, and passes the 6KV hipot test for dielectric performance.
Both coatings have undergone extensive testing for thermal and electrical performance. The Dielectric Gray variant meets UL 94 V0 and IEC 60243-1 standards, while the FG Black has passed direct flame, single-cell thermal runaway, and UL 2596 TaG tests. In direct flame tests at 1200°C, the FG Black coating neither ignited nor produced smoke.
Dr. Roop further noted that automakers are increasingly seeking solutions that enhance safety and durability. “Our customers are looking for technologies that can withstand extreme environments and support their efforts to build safe and reliable battery systems,” he said.
With the global EV market projected to exceed 20 million units by 2025, representing more than a quarter of all vehicles sold, Axalta’s new coatings are positioned to play a key role in improving battery resilience and consumer confidence.
Several major automotive OEMs and Tier 1 suppliers are already testing the coatings for integration into upcoming models.
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