Alkegen’s EV battery fire protection aerogels enter commercial production

Alkegen, a supplier of cell spacers, announced the full-scale commercial production of its proprietary fiber-enhanced aerogel insulation for electric vehicle (EV) battery fire protection.

This launch marks Alkegen's strategic product portfolio expansion for the EV market, delivering a comprehensive portfolio of advanced thermal and electrical insulation materials for original equipment manufacturers (OEMs). With the addition of aerogels to its offering, Alkegen now provides OEMs with end-to-end insulation solutions optimized for performance, design flexibility, and scalable production.

"We've taken a platform that's already proven itself in the industrial space and scaled it for one of the fastest-growing markets in the world—EV battery safety," says Alkegen CEO John Dandolph. "Automakers no longer have to rely on a single supplier in North America for this mission-critical solution."

At the heart of this expansion is AlkeGel, Alkegen's next-generation, high performance fiber-aerogel composite, engineered to meet OEM demand for ultra-thin, safe, and easy-to-install thermal runaway protection for lithium-ion battery systems. Unlike traditional aerogels, AlkeGel is low-dust, eliminating the need for full encapsulation and allowing for simpler and more cost-effective part designs that integrate more easily into space-constrained EV battery packs.

"Automakers need reliable, scalable partners. With AlkeGel, they now have a superior choice," says Chad Cannan, Alkegen's chief technology officer. "AlkeGel has proven to be significantly less dusty than traditional aerogel insulations – making it easier to convert, safer to handle, and more adaptable to complex part geometries."

With the addition of aerogels, Alkegen builds on its leadership in cell spacer technology to offer a full insulation portfolio – including wraps and thermal barriers – giving EV manufacturers the flexibility to match material to application.

"The EV industry has been waiting for a credible second source of battery fire protection aerogel insulation in North America," says Marty Melhorn, president, Battery Pack and Advanced Mobility. "AlkeGel is here. We're manufacturing at scale – and we're just getting started."

Key Highlights:

• Full commercial production of AlkeGel for EV battery anti thermal propagation materials
• Low-dust design simplifies handling, eliminates need for encapsulation, and reduces integration time
• Global footprint with strategic manufacturing locations in North America and Europe
• Complete insulation portfolio for EV platforms, including cell compression pads, wraps, and thermal barriers