At this year’s Future of Automotive Testing Conference, held as part of Automotive Testing Expo North America, Lakshmi Prasad Bhatta, manager of CAE at Mahindra Automotive North America’s Detroit MRV, discussed the engineering challenges and novel solutions for protecting high-voltage battery systems during collisions.
The electric vehicle revolution is reshaping automotive safety standards, with high-voltage battery systems emerging as a central focus. International organizations such as the Society of Automotive Engineers (SAE) and the International Organization for Standardization (ISO) play a crucial role in setting the benchmark for mechanical abuse and crash testing.
Bhatta, a seasoned crash safety engineer with over two decades of experience, has made significant contributions to this evolving field. Meeting baseline safety regulations such as FMVSS and UNECE is mandatory, but Bhatta emphasizes the importance of going beyond this. As a member of the US Technical Advisory Group (USTAG) for ISO standardization, he advocates for robust testing frameworks that address real-world risks. “SAE and ISO standards ensure we’re not just meeting requirements but anticipating challenges,” he explains.
Engineering solutions for high-stakes scenarios
Designing EVs to withstand crashes demands innovative engineering solutions. One critical area is preventing thermal runaway incidents caused by side impacts. These events can damage battery compartments and trigger chemical reactions within cells.
Bhatta’s patented side sill reinforcement design exemplifies how auto makers can balance intrusion prevention with crash energy absorption. This design not only shields the cabin and battery but also demonstrates how structural integrity can coexist with energy dissipation.
The complexity of EV safety testing is amplified by the interplay of mechanical, electrical and thermal dynamics during a crash. Multi-physics CAE tools offer a powerful solution, allowing engineers to simulate these variables and predict outcomes with remarkable accuracy.
“Simulations grounded in SAE and ISO protocols help identify vulnerabilities early in the design process,” Bhatta notes. By focusing on predictive modeling, manufacturers can reduce the need for exhaustive physical testing while maintaining safety integrity. However, Bhatta highlights the importance of complementing simulations with system-level tests to validate performance under real-world conditions.
Driving safety through global regulations and innovations
Global regulators are taking proactive steps to address EV battery safety. For example, India has recently adopted safety norms aligned with EU standards, introducing stringent criteria for battery pack performance. These regulatory frameworks push manufacturers to innovate, ensuring that EVs are safe and reliable.
Bhatta views this shift as essential. “Regulations set the foundation, but standards from SAE and ISO inspire manufacturers to exceed them,” he says, underscoring the symbiotic relationship between regulation and innovation.
The future of battery safety lies in advanced materials and designs. Lithium iron phosphate (LFP) batteries, known for their thermal stability, are gaining traction as a safer alternative to traditional lithium-ion batteries. Meanwhile, solid-state batteries represent a promising evolution, replacing flammable liquid electrolytes with non-flammable solid materials.
“The shift to these next-generation batteries represents a major leap forward in both safety and sustainability,” Bhatta observes, adding that these advances will pave the way for safer and more efficient EVs.
A holistic vision for EV safety
Bhatta emphasizes that battery safety extends beyond vehicles – it’s also about protecting first responders, infrastructure and communities. By fostering collaboration across stakeholders, from engineers to policymakers, the automotive industry can ensure a safer future for all.
“Safety is a shared responsibility, and we must remain committed to innovation and rigorous testing,” he concludes. This approach not only builds confidence in electric vehicles but also accelerates progress toward a more sustainable future.
Read more on automotive safety engineering in Crash Test Technology International magazine.
Look out for a feature on Mahindra Automotive North America‘s HV battery safety testing in the March 2025 edition of the magazine.