Did you know the South is emerging as one of the most important regions advancing the battery industry? That momentum was on full display at the inaugural The Battery Show South 2025 this week, April 16-17th, at the Georgia World Congress Center in Atlanta, Georgia.
The first edition of The Battery Show South brought the industry to the heart of the Battery Belt in Atlanta. Next stop: Detroit in October 6-9th, 2025.
The event brought together engineers, manufacturers, and technical experts to explore the next wave of battery innovation across electric vehicles, energy storage systems, and grid-connected technologies. Attendees also had access to four, immersive conference tracks covering topics such as advanced battery design, battery manufacturing development, supply chain forecasts, and more.
Co-located with the Electric & Hybrid Vehicle Technology Expo South and Energy Storage South, the event showcased advancements in cell and pack design, materials engineering, thermal management, and manufacturing automation.
The Battery Show South 2025 underscored the Southeast’s growing role in electrification and its impact on the future of energy storage and transportation.
Stretching across the Southeastern US, the “Battery Belt” isn’t just a cluster of gigafactories — it’s a strategic shift in how the auto industry approaches electrification. By bringing battery production, component testing, and vehicle assembly closer together, this region is accelerating innovation, reducing supply chain risk, and redefining what scalable EV manufacturing looks like in the US.
Below we bring you a snapshot of some of the products showcased this week, in no particular order. There will be plenty more to learn about when The Battery Show and EV Tech Expo are back in downtown Detroit on October 6-9th, 2025, celebrating their 15th anniversary. We hope to see you there!
A three-phase ac emulator
The SL1200A regenerative ac emulator series.
As vehicle-to-grid (V2G) technologies gain momentum, EVs are no longer positioned as just energy consumers, but also as flexible grid assets. Bidirectional charging opens up the potential for EVs to return power to the grid during peak demand, effectively functioning as distributed energy resources (DERs) in a growing network of localized microgrids.
Keysight Technologies’ SL1200A three-phase ac emulator addresses the increasing complexity of inverter testing in this landscape. Recent updates to the platform include new capabilities for real-time hardware-in-the-loop (HIL) simulation, such as anti-islanding behavior required for UL 1741 SA compliance. These updates allow engineers to emulate grid conditions (including RLC circuits) quickly and electronically, reducing test setup time from days to hours.
“Instead of physically configuring resistors, inductors, and capacitors, we’re now emulating those components in real-time,” said Antony Parulian, Business Development Manager eMobility and Energy Storage with Keysight Technologies. “This dramatically reduces setup time and allows engineers to simulate complex grid scenarios more efficiently — especially when testing EV charging and vehicle-to-grid systems for compliance with standards like UL 1741 SA.”
Battery simulator module
Pickering has introduced new PXI and PXIe battery simulator modules designed to streamline testing and validation of battery management systems (BMS) in electric vehicles. The 41-752A (PXI) and 43-752A (PXIe) modules feature up to six independent battery cell simulators per slot, with each channel capable of sourcing current and providing accurate voltage output.
These modules are well-suited for simulating the stacked-cell configurations used in EV propulsion systems.
The PXI/PXIe battery simulator module.
“These battery systems require specific charging routines, which rely on intelligent BMS for safe and efficient charge and discharge cycles,” said Paul Bovingdon, Simulation Product Manager, with Pickering. “One of the major challenges is effective BMS testing, and until now, engineers often had to link external DMMs to simulation modules to get voltage and current readback. Our new modules eliminate that need, making setups simpler and more accurate.”
With isolation up to 1,000 volts, test engineers can simulate over 100 battery cells within a single chassis. The improved voltage accuracy also supports newer battery chemistries, and the modules integrate easily with Pickering’s wider PXI simulation and switching solutions to build scalable, high-fidelity EV test systems.
High-voltage arcing protection
Oerlikon’s TX700 high-temperature, electrically insulating barrier material.
Oerlikon’s TX700 is a high-temperature, electrically insulating barrier material engineered for arcing protection in high-voltage EV battery systems. With a thickness of just 0.2 mm, it withstands temperatures up to 1000° C, offering a compact solution for enhancing safety in densely packed battery assemblies.
The material’s ultra-thin, flexible profile enables its use in tight spaces without compromising performance.
TX700 effectively blocks high-voltage arcing, protecting key battery components, including cells, modules, and enclosure covers.
Part of a broader portfolio focused on thermoelectrical insulation, TX700 contributes to system-level safety by preventing electrical discharge across surfaces within the battery architecture. Its durability and heat resistance make it suitable for next-generation EV platforms where thermal stress and electrical clearance are critical design factors.
Electrical insulation for EV motors
Nomex 710 insulation paper supports high-temperature, high-density EV motor designs.
DuPont Nomex 710 is a high-temperature capable, chemically resistant electrical insulation paper designed for the performance and production requirements of electric vehicle (EV) traction motors.
With an initial thickness of 0.22 mm (8.5 mils), Nomex 710 enables insulation of hairpin and round wire motor designs, helping engineers maximize copper fill and achieve higher power density within compact motor architectures.
Compared to Nomex 410 — DuPont’s widely used insulation paper for general electrical applications — Nomex 710 offers improved mechanical strength at reduced thicknesses, supporting automated manufacturing processes such as slot liner insertion. Its electrical and thermal performance makes it suitable for optimizing EV stator designs for higher power output or size reduction without compromising system reliability.
“DuPont Nomex provides a variety of insulation products for electric motors,” said David Buzzelli, Global Marketing Leader with DuPont. “The new Nomex 710 portfolio allows motor designers to choose from various Nomex insulation thicknesses, depending on their unique design needs.”
Nomex 710 meets growing demands for advanced insulation materials that can withstand the stresses of high-speed EV propulsion systems while contributing to efficient motor design and manufacturability.
Bidirectional power supply streamlines EV testing
EV systems demand test platforms that support bidirectional energy flow, regenerative operation, and precise control across a wide power range. The Chroma 62000D Series bidirectional dc power supply functions as a power source, regenerative load, battery emulator, and fuel cell emulator, making it suitable for a wide range of EV component testing.
“You can use it as a battery cycler by adding a controller with logging, EMS communication, and watchdog circuits,” said Jonathan McCallie, Sales Director at Chroma Systems Solutions, Inc.
The Chroma 62000D Series bidirectional dc power supply and regenerative battery pack test.
The series covers voltages up to 2,000 V and currents up to 1,440 A, with power scalability up to 1 MW. Dual-range models support testing across 400 V and 800 V EV architectures without switching equipment. Fast transient response, up to 45 kW in a 4U chassis, and compliance with standards like LV123 and LV148 enable accurate and efficient validation of onboard chargers, dc-dc converters, motor drives, and full battery packs.
Chroma’s software ecosystem extends the platform’s capabilities with integrated battery profiles and advanced test automation.
“What’s unique is that you’re emulating RLC circuits electronically instead of manually tuning components,” McCallie added. “That cuts setup time for hardware-in-the-loop testing from days to just a few hours.”
Programmable dc power supplies
TDK-Lambda’s GENESYS+ Series of programmable dc power supplies provides a flexible, high-density electric vehicle (EV) system development, testing, and validation solution. With output voltages from 10 to 1500 V and current up to 1500 A, the series suits various EV applications, including battery pack testing, BMS verification, dc-dc converter development, and high-voltage component validation.
The GENESYS+ Series of programmable dc power supplies.
Available in 1U to 3U form factors and covering power levels from 1 kW to 22.5 kW, GENESYS+ models include built-in LAN, USB, RS-232/485, and isolated analog control (5 V/10 V), with optional IEEE, EtherCAT, Modbus-TCP, and 4–20 mA input interfaces. These options support integration into automated test benches, HIL setups, and production test environments.
Advanced features include programmable voltage and current slew-rate control, constant power limit modes, internal resistance simulation, arbitrary waveform generation, and pre-load control.
With active power factor correction, multiple AC input configurations, and safety certifications that meet global compliance standards, TDK-Lambda’s GENESYS+ Series is designed to support the evolving demands of EV power electronics and battery systems with precision and reliability.
Joining forces to streamline EV battery testing
As electric vehicle (EV) development accelerates, maintaining precise thermal and environmental conditions during battery testing is essential for ensuring safety, reliability, and performance.
Chiller from Huber USA and chamber from Binder Inc. shown at The Battery Show South, working together to support stable thermal conditions in battery testing.
Huber USA and Binder Inc. have partnered to deliver integrated solutions that streamline the testing ecosystem — pairing Huber’s high-precision chillers with Binder’s advanced environmental chambers to support rigorous validation of EV batteries.
Together, the companies cover two of the three core components of a battery testing setup: chillers and climate chambers.
“Any part of a battery-testing ecosystem needs a chiller, a chamber, and a cycler, and we represent two of those three important pieces,” said Joshua Persaud, Head of Sales at Binder, during The Battery Show South. “What would be important to the engineers is the stability of the part you work on. The Huber chiller stabilizes the temperature for the Binder chamber, so you don’t have alterations, and you have more uniformity.”
By offering systems that already communicate effectively and operate in tandem, the partnership helps simplify procurement, integration, and performance tuning for engineers building or scaling battery testing platforms. Solutions from both companies also support sustainability goals by using natural refrigerants and energy-efficient designs, meeting the dual demands of test performance and eco-conscious manufacturing.
Insulating and safeguarding EV components
The ITW Formex GK is a flame-retardant polypropylene insulation material engineered for the electrical, environmental, and mechanical requirements of electric vehicle (EV) systems.
Formex GK insulation material provides electrical protection and mechanical strength for EV components, with a flexible form factor suited for compact system designs.
With high dielectric strength, a UL 94 V-0 flame rating, and resistance to moisture and chemicals, it serves as a flexible insulation solution for battery management systems (BMS), control electronics, and other high-voltage components within EV platforms.
The material is easily fabricated into complex shapes or folded into three-dimensional forms, supporting integration into compact or uniquely shaped enclosures. This design flexibility makes it suitable for a wide range of EV architectures, especially where precise fit and rapid assembly are critical.
Tested under UL 746C protocols for UV stability, water exposure, and immersion, ITW Formex GK meets global compliance standards, including RoHS, REACH, and WEEE. Its adoption across the EV industry highlights its role in supporting safe, space-efficient insulation in electric mobility applications.
Adhesives for more efficient EV manufacturing
Panacol’s latest developments in the field of e-mobility and automotive electronics include adhesives for the stress relief of wires on commutators, bonding of magnets in electric motors, and balance compensation in fan rotors.
Panacol adhesives are developed for fast, reliable bonding of EV components.
For commutator applications, UV adhesives in the company’s Vitralit range are particularly effective for relieving stress on wire connections. These adhesives can be applied directly to the wire/commutator junction and cured within seconds using UV light, making them well-suited for high-volume production with short cycle times.
Newly developed dual-curing adhesives (activated by UV and moisture) are used for bonding magnets in electric motors. While the magnet’s opacity blocks direct UV exposure, curing of the adhesive “squeeze-out” secures the part in place. The adhesive underneath, including in shaded rotor pockets, completes curing through exposure to atmospheric and surface moisture. All curing occurs at room temperature.
Panacol also offers a high-density, fast-curing acrylate adhesive for balancing fan rotors. Jet-dispensed into balancing pockets, the adhesive allows for accurate mass correction without metal weights, significantly reducing cycle times and scrap rates.
Made-in-America commercial EV battery
BorgWarner’s 9 AKM 150 CYC battery system delivers a high-capacity, modular energy solution for electric commercial vehicles.
BorgWarner’s 9 AKM 150 CYC battery system.
With 98 kWh of total capacity, the system is built from nine CYC modules based on the 21700-format cylindrical lithium-ion cell. Each module includes 600 cells configured in a 20s30p arrangement, achieving approximately 221 Wh/kg in energy density while maintaining a safe voltage for production and service.
Manufactured in Seneca, South Carolina, the battery pack is fully Buy America compliant — a key factor for public transit fleets and industrial vehicle platforms seeking domestically sourced electrification solutions.
“It’s a 98-kilowatt-hour max capacity battery system for commercial vehicles, both on-highway and off-road,” said Paul Gumber, Sales Manager at BorgWarner Battery Systems. “We produce this with 2,400 NMC cells at our two gigawatt-hour facility in the US, and we’re proud to supply the American market.”
With an operating range of 520 to 756 V and nominal voltage of 665 V, the system offers high power in a compact form, suitable for heavy-duty vehicles including buses, off-road machinery, and marine applications. It supports scalable system capacities up to 1,000 kWh, depending on vehicle size and use case.
The battery system is also customizable to meet specific OEM integration needs, offering flexibility in layout and thermal management approaches.
Filed Under: Batteries, FAQs, Technology News