India’s push toward electric mobility has entered a new phase with Sundha Polymers leading an ambitious project to redefine EV Battery Housing safety. As of July 2025, Sundha’s advanced R&D division has made notable progress in developing next-generation fireproof composite enclosures for electric vehicle batteries. This innovation is set to tackle one of the EV industry’s most pressing challenges—battery fire risks—by integrating fireproof composite use into structural design without adding significant weight.
This technological development comes in response to global concerns over EV battery safety, especially in tropical regions like India, where extreme temperatures and rough terrains increase the likelihood of thermal incidents. Sundha’s new design is lightweight, impact-resistant, and capable of withstanding temperatures over 1000°C, setting new benchmarks for Indian EV manufacturing.
What Makes the New EV Battery Housing Unique?
Sundha’s breakthrough involves a layered composite structure made from reinforced thermosetting resins, glass fiber mats, and ceramic-based flame barriers. Unlike conventional aluminum casings, which are prone to warping or melting under severe heat, these housings maintain structural integrity even during cell failures.
Key features of the EV Battery Housing system include:
-
Non-metallic shell resistant to thermal runaway
-
High dielectric strength for shock protection
-
Weight reduction by 25% compared to metal housings
-
Integrated cooling pathways and pressure relief vents
-
Sustainable materials to support eco-friendly EV manufacturing
This marks one of the first large-scale efforts in India toward fireproof composite use in electric vehicle applications, reducing the chances of post-collision fires and ensuring greater safety for drivers and passengers alike.
Comparison with Traditional Battery Housings
To better understand the advantages, here is a comparison between traditional aluminum housings and Sundha’s upcoming EV Battery Housing system featuring fireproof composite use:
| Feature | Traditional Aluminum Housing | Sundha Fireproof Composite Housing |
|---|---|---|
| Weight | Heavy (adds ~90kg per unit) | Lightweight (~65kg per unit) |
| Heat Resistance | Up to 300°C | Over 1000°C |
| Electrical Insulation | Moderate | Excellent |
| Environmental Impact | High (mining, processing) | Low (recyclable, polymer-based) |
| Manufacturing Complexity | Moderate | Higher (requires specialized molding) |
| Cooling Integration | Add-on | Built-in |
Industrial Partnerships and Testing Phase
Currently, Sundha Polymers is collaborating with four Indian OEMs and two Tier-1 battery pack integrators to validate the new EV Battery Housing units across diverse vehicle platforms—ranging from two-wheelers to commercial vans. Rigorous testing protocols include drop tests, fire chamber endurance, water immersion, and pressure venting simulations.
Implementation milestones:
-
Completion of prototype line by August 2025
-
Crash and fire simulations in collaboration with IIT Madras
-
Commercial rollout expected in Q2 2026
-
First deployment in electric scooters and microvans
The integration of fireproof composite use is also supported by India’s Ministry of Heavy Industries, which is offering R&D incentives under the FAME III policy to improve EV battery safety through advanced material innovation.
Environmental and Economic Advantages
In addition to safety benefits, the shift to polymer-based EV Battery Housing also contributes to sustainability. The composite materials being used are partially bio-based, have a lower carbon footprint in production, and are easier to recycle compared to metal casings.
Benefits of fireproof composite designs:
-
Lower lifecycle CO₂ emissions
-
Easier end-of-life battery pack disassembly
-
Reduced reliance on aluminum mining and smelting
-
Faster molding reduces energy consumption in manufacturing
With these features, Sundha’s product is not only a technical upgrade—it also aligns with India’s net-zero vision and circular economy ambitions in the EV sector.
Conclusion
The development of Sundha’s advanced EV Battery Housing using fireproof composite use is a pivotal moment for India’s electric mobility journey. By addressing one of the most critical concerns in EV adoption—fire safety—this innovation has the potential to elevate consumer confidence, attract international collaborations, and place India on the global map for advanced EV materials. With testing underway and deployment set for 2026, the future of EV safety looks brighter, lighter, and far more resilient.
FAQs
What is EV Battery Housing?
It is the protective enclosure around an EV’s battery pack, designed to shield it from impact, heat, and environmental hazards.
Why is fireproof composite use important?
It reduces the risk of thermal runaway and fires in electric vehicles, making them safer for users and compliant with global safety standards.
When will Sundha’s battery housing be available commercially?
Pilot rollout is planned in early 2026, starting with select two-wheeler and light commercial EVs.
Are these battery housings recyclable?
Yes, they are made from partially bio-based polymers and fiberglass, which can be separated and repurposed more easily than metals.
Will this increase the cost of EVs?
Initially, the cost might be slightly higher due to advanced materials, but large-scale manufacturing is expected to make it cost-neutral by late 2026.
Click here to know more