The Hidden Risks in EV Production (and How to Avoid Them)
Thermal Management and Materials Strategy: The Make-or-Break Factors for EV Scaling.
Written Arturo Nunez, Saunders Sales Manager
New Pressures Caused by EV Production
The electric vehicle (EV) market is growing fast, with battery demand expected to more than triple by 2030. EVs are the main driver of that increase. But with that growth comes risk: recalls from battery failures, downtime from weak materials and uncertainty about which chemistries will win long term.
Optimizing Batteries with Thermal Management
The biggest challenge I see is thermal management. Batteries generate heat. If the right materials to seal, insulate and protect them aren’t chosen, you risk performance loss, safety incidents or complete shutdown. Changing chemistries also present challenges. Lithium-ion phosphate batteries (LFP) behave differently from nickel manganese cobalt batteries (NMC). Solid-state brings another set of requirements. Each demands specific insulation, gasketing and shielding strategies.
On top of all of that, new policies are forcing U.S. OEMs to reevaluate their battery supply chains. In July 2025, Motortrend reported a “strong drive and significant investment by private industry and more recently via public policy to boost stateside battery production.” But with a limited number of U.S.-based factories, we still have a ways to go.
So where should manufacturers turn? Partnerships. Last year, the S&P Global reported that “[OEM] sourcing through partnerships is expected to increase from 7% in 2022 to 26% in 2030.” Partnerships balance risk against the expense of a vertically integrated battery supply chain.
While sourcing strategies and partnerships set the stage, the real test comes when prototypes scale to production and hidden risks emerge. This is where thermal management decisions make the biggest difference.
From Prototype to Production
Manufacturers that solve thermal demands early reduce recall risk and extend product life. Essential, but complex, flexible, non-metallic materials can improve product longevity and safety. Proven solutions include advanced cooling systems, thermal insulation and sealing and gasketing. But each customer and each application are unique.
Moving from prototype to production often exposes weak points in design. Fixing them late in the process costs time and money—making it smart to test material expansion rates at the prototype stage. Don’t wait until full production, when design changes are far more expensive.
Avoiding Common Mistakes In EV Production
Too often, manufacturers overlook the basics. One mistake is underestimating how much coefficient of thermal expansion matters. If materials expand at different rates, parts fail. Another misconception is treating cold conditions as less critical than heat. Cold is just as dangerous. Test for both, or you’ll pay for it later. The right partner should catch these issues early and help keep your design on track.
Scaling Into the Future of EV Manufacturing
Looking ahead, EV manufacturing will only get tougher. Solid-state batteries, new regulations and the race to scale will demand better strategies and faster adaptation. Companies that work closely with manufacturing partners and suppliers will stay ahead.
Another challenge on the horizon is battery waste. As adoption grows, so will the number of packs reaching end of life. Adhesives are a good example: they’re essential for thermal and mechanical performance, but they can make recycling harder if they aren’t designed with end-of-life in mind. The next generation of materials will need to perform reliably in service while also allowing dismantling when it’s time to recycle. Manufacturers that factor sustainability into today’s designs won’t just reduce risk—they’ll be positioned to scale more responsibly and lead the industry forward.
At Saunders, we’re more than a global leader in material selection and manufacturing custom-cut engineered EV and battery components. By training our people and investing in technology for high-volume EV production, we give customers confidence in quality at scale. As EV manufacturing grows more complex—with solid-state batteries, new regulations and the race to scale—success will depend on strong partnerships. Thermal management is central to that challenge, and Saunders is focused on aligning materials to applications in ways that help customers solve problems and scale faster.
Let’s Find Your EV Solutions
Saunders, by R.S. Hughes, stands Behind Every Build—helping EV and battery manufacturers solve today’s problems and prepare for what’s next. And we’re putting money into the technology that matters most for EV manufacturing—tools that let us run high volumes reliably without sacrificing quality. EV manufacturers don’t just need prototypes. They need partners who can scale with them. That’s what we’re building at Saunders.
If you’re facing thermal management challenges or scaling pressures, let’s talk.
