Alkegen, a global leader in advanced battery materials, has announced the full-scale commercial production of its proprietary fiber-enhanced aerogel insulation, AlkeGel™, engineered specifically for electric vehicle (EV) battery fire protection. This marks a major strategic expansion of the company’s thermal and electrical insulation offerings for OEMs across the EV sector.
AlkeGel™ is Alkegen’s next-generation, low-dust, fiber-aerogel composite that delivers ultra-thin, lightweight, and high-performance thermal runaway protection. The material’s unique formulation allows for safe and easy installation into EV battery packs without the need for full encapsulation, significantly simplifying design and reducing integration costs.
A Critical Step Forward for EV Battery Safety
“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,” said John Dandolph, CEO of Alkegen. “Automakers no longer have to rely on a single supplier in North America for this mission-critical solution.”
AlkeGel™ is specifically designed to address the growing concerns of thermal propagation in lithium-ion battery systems, where a single cell failure can escalate into a full battery fire. The material is reported to be significantly less dusty than traditional aerogels, making it easier and safer to work with during battery pack assembly.
“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,” added Chad Cannan, Chief Technology Officer at Alkegen.
Enabling Next-Gen EV Designs
With its entry into commercial aerogel production, Alkegen now offers OEMs a complete insulation portfolio for EV battery systems—including cell compression pads, wraps, and thermal barriers—offering unmatched flexibility and performance across multiple EV platforms.
“The EV industry has been waiting for a credible second source of battery fire protection aerogel insulation in North America,” said Marty Melhorn, President of Battery Pack and Advanced Mobility. “AlkeGel™ is here. We’re manufacturing at scale—and we’re just getting started.”
Key Highlights:
- Commercial production underway for AlkeGel™, Alkegen’s thermal runaway protection material
- Low-dust composition eliminates need for encapsulation, simplifies handling and installation
- Global manufacturing footprint, with facilities in North America and Europe
- Full insulation portfolio now available, including cell spacers, wraps, and thermal barriers
With EV demand skyrocketing and battery safety under global scrutiny, Alkegen’s expanded capabilities position it as a pivotal supplier in the evolving electric mobility ecosystem. Through innovations like AlkeGel™, the company aims to support safer, more reliable, and cost-effective electric vehicle platforms.
