PyroThin® Aerogel Thermal Barrier
Design & Development
We engineer confidence
Cell barriers are a mission-critical part of any EV design. When planning your thermal propagation mitigation strategy, choose a proven partner that is flexible and can perform under pressure.
Aspen Aerogels is a Tier 1 automotive supplier that manages every aspect of our PyroThin® cell barriers in-house, from formulating our proprietary aerogel chemistry to fabricating the finished part. Our rapid prototyping and material testing capabilities ensure a thermal runaway solution to meet your production schedule and quality standards, no matter the design changes.
In-house testing accelerates development with a closed–loop feedback system
Meet our advanced testing team
Battery packs and modules are complex systems, so there is no one-size-fits-all test to evaluate cell barrier performance through end-of-life (EOL). For non-standard tests, our Specialty Test Services team is dedicated to helping solve your most complex challenges.
Our testing team can help you asses and better understand part performance including but not limited to:
- EOL behavior: Modified compression set testing, cyclic fatigue
- Abrasive blast performance: Customized torch and grit test
- Thermal performance: ASTM C177 and ASTM C518 thermal conductivity at high-temperature, thermal performance under load
For larger-scale thermal runaway testing, we collaborate with a trusted third-party partner to execute the more explosive tests designed by our experts.
Rapid-prototyping capabilities to help you meet any and all program milestones with confidence
Leading thermal propagation engineering expertise
The Advanced Thermal Barrier Center serves as our global engineering hub, backed by expert teams in Europe and Asia. We collaborate closely with automotive and battery manufacturers, giving us expertise across pack configurations and cell chemistries, including LFP, mid-nickel, NMC811, and beyond. Our comprehensive knowledge and hands-on experience make us a trusted leader in thermal runaway mitigation solutions.
In-house tooling capabilities
Design changes are inevitable at any stage of development. With in-house tooling development and fabrication, we provide the flexibility and speed to support your team as designs evolve and prototype samples become critical to the program’s success.
24-hour sample turnaround
When called upon, we can quickly turn around small-volume sample orders, ensuring you get the parts you need when testing at critical stages of development. Our in-house tooling and manufacturing capabilities allow us to adapt to design changes seamlessly, keeping your project on track without delays.
Visit our R&D and prototyping facilities to unlock the true potential of your application
We invite automotive and battery manufacturers to our headquarters and engineering facilities, located 45 minutes outside of Boston, to collaborate on programs in any stage of development.
- Transform an idea into reality: Our rapid prototyping capabilities enable you to arrive at our facilities with a concept and leave with sample parts ready for testing.
- Experience your parts in real-time: Hands-on experience with your parts is invaluable, offering your team a clearer understanding to bridge reality with simulation models.
- Save time & resources: An in-person visit optimizes your team’s efficiency, allowing them to streamline potentially weeks of work into several days.