Blue Solutions and AVL have undertaken a joint evaluation program to advance battery safety for next-generation cell technologies as they move toward industrial scale-up.
The collaborative program set out to anticipate the safety behaviors of solid-state battery cells under increasingly demanding operational and regulatory conditions, and address technology-specific requirements, including pressure management and mechanical integrity at the cell and system levels.
The initiative combined Blue Solutions’ battery cell technology and AVL’s expertise in battery simulation, validation and safety assessment. Conducted on a non-exclusive basis, the collaboration allowed both partners to strengthen their programs while continuing to support broader industry progress.
Anticipating safety at scale
As battery technologies evolve toward higher performance and higher volumetric energy density, the joint program confirmed that safety can be embedded early in the design process.
The work focused on predictive safety simulations during cell technology scale-up, and evaluated technology-specific behaviors, including internal pressure management. Advanced abuse and failure scenario modeling, and alignment with emerging safety regulations, were also studied.
Toward thermal-propagation-free battery systems
The program also addressed thermal propagation (TP). By combining advanced modeling, pressure-aware design and safety-first architecture, the partners demonstrated pathways toward eliminating thermal propagation risks.
Simulation-based and validation test results demonstrated positive and consistent outcomes, including compliance even under the latest New Energy Vehicle regulations. The technology meets the GB 38031-2025 requirements.
The program confirmed that the intrinsically high volumetric energy density of Blue Solutions’ technology is safeguarded, while maintaining robust safety margins. Results demonstrated targets of up to 25% higher volumetric energy density compared with equivalent NMC Li-ion battery packs, alongside an expected 13% increase in gravimetric energy density.
Results and key lessons learned will be disseminated at leading international conferences and battery industry events.
“We are very happy to have collaborated with AVL,” said Olivier Caumont, battery systems director at Blue Solutions. “Their vision and mastery in multiple sectors, combined with our extensive manufacturing experience in solid-state battery manufacturing and pack integration, including the safety, thermal or mechanical aspects, have enabled us to confirm that our solution is fully aligned with market needs, and capable of fulfilling the most stringent safety requirements.”
“Working with Blue Solutions’ latest solid-state battery technology is a significant step forward for AVL,” added Paul Schiffbänker, director of battery development at AVL List. “It not only deepens our understanding of the specific safety characteristics of this next-generation chemistry but also actively drives the further development of our safety methodologies and battery design solutions. From advanced simulation-based prediction models to new validation and assessment approaches, this collaboration enables us to systematically embed safety into the development of future high-energy battery systems from the very beginning.”
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