Autoneum is advancing battery protection for battery electric vehicles (BEVs) with a portfolio of lightweight composite solutions that enhance safety, thermal management, and efficiency. The company’s new battery lid serves as an adaptable top cover for battery packs, integrating functions such as flame protection and electromagnetic shielding.
Produced using Spray Transfer Molding (STM) with glass-fiber reinforcement and a polyurethane matrix, the design delivers high mechanical strength, supports complex geometries, and enables fast production cycles while reducing weight by up to 30% compared with conventional solutions. Derived from Autoneum’s flame shield technology, the mica-free battery lid provides structural integrity, electrical insulation, and improved thermal runaway containment while addressing sustainability and supply-chain concerns.
The company’s E-Fiber flame shield, installed inside the battery housing, acts as a thermal barrier between battery cells and the vehicle interior. Constructed from glass-fiber composite material, it withstands temperatures up to 1,400°C and resists hot particles and gas pressure generated during thermal runaway events. Compared with traditional mica-based materials, the lighter, less brittle design also provides essential electrical insulation.
For underbody protection, Autoneum’s impact protection plate uses long-fiber thermoplastic technology to protect battery packs from collisions, debris, fire, and corrosion. The lightweight composite combines stiffness with thermal insulation, improving energy efficiency and driving range while maintaining durability through repeated impacts. The process also enables waste-free manufacturing and design flexibility.
The under-battery shield also incorporates Ultra-Silent textile technology to improve thermal insulation, reduce heat loss and rolling noise, and protect against stone chipping. Made entirely from polyester with up to 70% recycled content, the recyclable shield supports zero-waste manufacturing and contributes to enhanced battery range, charging performance, and lifecycle durability. “Our new battery lid represents a step-change in battery housing technology for electric vehicles,” said Luca Mazzarella, Head New Mobility at Autoneum. “By integrating advanced composite materials and multifunctional design, we are able to offer OEMs and partners a solution that elevates safety and efficiency, while addressing the demands of future BEV platforms.”
