Innovation: Self-Sensing and Adaptive Dual Matrix Composite EV Battery Enclosure

Award Category: Unsurpassed Innovation, 2025 CAMX Award Winner

Company: Helicoid Industries

Objective: Our enclosure marries a biomimetic Helicoid™ composite layup to a dual-matrix resin system that self-activate and self-adapt by softening above a certain temperature threshold and enabling enhanced absorbed blast pressure during Thermal Runaway, while a topology-optimized, 3D printed cooling core actively extracts heat.

Results: Tests showed >100% energy dissipation gain, 60% less back face dent, >60% more load capacity, 45% tighter ΔT and 15% lower peak cell temperature versus a standard cold plate baseline.

Impact: The result is a sandwich enclosure that integrates cooling, fire containment and crash protection, replacing a multi-component aluminum assembly with one lightweight, compact component.

From the Expert: Lorenzo Mencattelli, Managing Director of Tech & Ops Helicoid Industries: “Initially when we started thinking about this concept, it was an extremely challenging idea. Lots of things that may go wrong given the combination of high-temperature and a very dynamic event such as thermal runaway. But then we submitted the idea to a program from the Department of Energy. They recognized the value of the idea, and these are actually the results of a SBIR Phase I of the program. We now look forward to a complete product development with Phase II.”

“Winning this award on the most important stage for the composites industry in North America is a real honor. We have plenty of activities in EV cars and other automotive components. So, this will definitely be a focus point for us in terms of strategies to mitigate thermal runaway.”

Learn more: https://helicoidind.com