Axalta Coating Systems, a global coatings company, will debut two new products at The Battery Show North America (Booth 1638): Alesta e-PRO FG Black and Alesta e-PRO Dielectric Gray. Both are part of Axalta’s growing portfolio of coatings developed for electric vehicle (EV) batteries and energy storage systems, offering improved thermal stability and electrical insulation performance.
As EVs become more common, battery safety remains a priority for manufacturers. While thermal runaway events are rare, they can cause extreme heat, fire, or structural damage if not properly contained. When used within validated OEM battery systems, these new coatings are designed to help improve resistance to such events by managing heat and maintaining electrical insulation.
Extreme heat protection
Alesta e-PRO FG Black is a powder coating formulated for thermal stability and secondary fire protection in EV battery systems. It is designed to resist ignition, expansion, and smoke generation under direct flame exposure and at temperatures reaching up to 1200° C, helping to delay or prevent fire propagation during thermal events.
Key features:
- Maintains thermal integrity under direct flame and extreme heat (600–1200° C)
- Produces no smoke at high temperatures Provides corrosion protection as a standalone coating or over electrocoated substrates
Electrical insulation performance
Alesta e-PRO Dielectric Gray is an epoxy-based powder coating that provides strong electrical insulation in high-voltage applications, including EV battery packs and stationary energy storage systems.
Key features:
- Uniform edge coverage ensures consistent insulation and high hipot test pass rates
- Flexible coating that accommodates complex geometries with reduced cracking risk
- High lap shear strength for structural stability under stress
- Achieves 6-kV hipot dielectric performance
Testing and validation
Both coatings have undergone extensive testing for electrical insulation, thermal resistance, and flame exposure.
- Dielectric Gray tested to UL 94 V0 and IEC 60243-1 standards
- FG Black tested for direct flame exposure, single-cell thermal runaway, and UL 2596 TaG conditions
Under direct flame at 1200° C, FG Black produces no smoke and resists ignition, demonstrating its suitability for EV battery protection applications.
These coatings are designed for use by global automotive manufacturers producing electric vehicles, supporting efforts to enhance safety, reliability, and performance in advanced battery systems. Several OEMs and Tier 1 suppliers are conducting additional evaluations as part of their design validation and pre-production testing.
Axalta was recently named to TIME magazine’s list of America’s Best Midsize Companies of 2025, which recognizes companies for employee satisfaction, revenue growth, and sustainability transparency.
Filed Under: Technology News