How Materials Science is Enhancing Battery Performance in EVs

In an exclusive interaction with Industry Outlook, Siddhartha Ghosal, CEO and Country President of Dow India, discusses how materials science supports EV battery assembly by enhancing thermal management, safety, and durability through specialized materials, while also addressing sustainability and evolving market demands with innovative, application-specific formulations and environmentally responsible manufacturing practices. With over two decades of experience in the chemical industry, Siddhartha Ghosal is a seasoned leader specializing in innovation, sustainability, and commercial operations, with a proven track record of driving growth through science-based solutions across the packaging, mobility, and infrastructure sectors.

How is materials science contributing to battery assembly?

Specialized materials – such as adhesives, sealants, polyurethane and silicone foams, and pottants – are essential to both the assembly and effectiveness of electric vehicles’ batteries. During assembly, high-strength, thermally conductive adhesives help ensure that batteries consistently deliver their intended range and charging speed over the vehicle’s lifespan while also supporting efficient manufacturing processes.

Pottants and foams contribute to battery durability and longevity, and help prevent the spread of abnormal thermal events from one cell to others. Sealants are also critical to battery safety and reliability by keeping out water and road debris, and by allowing for proper venting of gases in the rare case of thermal runaway within a cell.

What are the key challenges faced in battery assembly for electric vehicles (EVs)?  How are companies addressing the technical challenges in battery assembly?

Thermal management is one of the most critical areas where materials can make a significant impact. As battery technology advances to facilitate higher power density and faster charging, managing heat becomes essential for maintaining long-term performance and reliability. Thermally conductive materials – both silicone- and polyurethane-based – are vital in assembling next-generation, high energy-density, fast-charging battery packs.

Polyurethanes are regularly selected for their outstanding strength and bonding capabilities. At the same time, silicones provide excellent thermal stability and reliability across wide temperature ranges, helping prevent mechanical property shifts that could end in failure. Choosing the right material, specifically formulated for the application, is crucial for efficient assembly and for maximizing performance and durability over time.

How are companies ensuring the safety and reliability of batteries through assembly processes?

Thermal-runaway protection standards are constantly evolving, which makes selecting durable and adaptable materials more important than ever. Silicone foams are especially effective in this area thanks to their natural resistance to heat and fire, rapid room-temperature curing, and partial inorganic makeup – primarily silicon oxide – which gives them an unparalleled ability to encapsulate and self-extinguish, significantly reducing the risk of thermal propagation. Their flexible formulation and application make them highly customizable for a wide range of cell types, module layouts, and pack configurations – offering a tailored yet cost-effective solution.

Depending on the battery’s cell type, size, and pack design, polyurethane foams also play a role in thermal insulation, helping to block thermal propagation. In practice, multiple material types are often combined to facilitate maximum safety, minimal weight impact, and optimized cost efficiency.

How are manufacturers addressing sustainability in battery assembly?

The most important consideration for implementing sustainable assembly practices is the material itself. By formulating materials in the right way, manufacturers can not only minimize material loss during the battery assembly process but also enable the material to be reclaimed efficiently at the end of the battery’s usable life.

Manufacturers are also looking to increasingly power assembly operations with renewable energy sources, which plays a major part in reducing emissions throughout the battery’s lifecycle. It is measures like these that make a critical difference in lowering customers’ scope-emissions, and helping businesses fulfil their sustainability obligations.

What are the market trends and predictions for EV battery assembly?

Electric vehicles bring unique challenges that demand stronger, more consistent bonding to an expanding range of substrates – including aluminium, e-coat, PET, PP, and more. Innovating effective materials in this space is a significant challenge for manufacturers to negotiate.

For example, to combat the effects of vibration, we’ve engineered high-strength adhesives, available in both standard and thermally conductive formulations, to deliver long-term durability under the vibrational stresses vehicles experience on varying road conditions. This leads to safer, more dependable battery packs.

Simultaneously, the industry must stay sharply focused on advancing sustainable practices. That’s why we’re reducing emissions through bio-based components and actively developing materials that support circularity.

As these challenges evolve, so must our solutions – and smart, purpose-driven material formulation is more essential than ever to help the industry move toward a more sustainable future.