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Aluminum Foam Makes Battery Cases Lighter and Safer

  • 28-11-2025
  • Battery
  • Editor´s Pick
  • News
Author
Mathias Keiber
30 sec reading time

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A novel sandwich material promises greater safety and efficiency for electric car batteries. However, series production depends on one crucial factor.

Possible housing design. In the four chambers from left to right: pure AAS, AAS with infiltrated PCM, AAS with cooling structure, AAS with cooling structure and PCM.


Fraunhofer IWU

At the Battery Show North America, the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) and supplier Amsted presented a concept for battery housings based on aluminum-aluminum foam sandwiches (AAS). The aim is to improve the safety and efficiency of high-voltage storage systems in electric cars in the future.

The structure consists of two solid aluminum sheets and a core of aluminum foam. Depending on requirements, cooling structures or phase change materials (PCM) can be integrated to store and release thermal energy.

The material combination is designed to meet key requirements for battery housings: high impact resistance, thermal management, protection against environmental influences, and low weight. The focus is now on cost-effectiveness for possible series production. Fraunhofer IWU wants to make greater use of recycled materials to reduce costs and CO₂ emissions.

This is a partly automated translation of this german article.

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Background information for this content

Characterization of Layered Hybrid Foam Formed by Aluminum Foam/EPS-Filled Syntactic Foam: Flexural Test Results

  • Open Access
  • Research Article-Mechanical Engineering

This research was designed to carry out the production, testing, and analysis of new layered hybrid foams obtained by joining closed-cell aluminum foam with expanded polystyrene (EPS)-filled syntactic foams. The mechanical properties of these new …

Effect of High Strain Rate and Temperature on the Mechanical Response of Graphene-Reinforced Aluminum Foam

  • Original Research Article

Closed-cell aluminum foam is a particular type of lightweight metallic material that can sustain considerable deformation under nearly constant stress, which is known as plateau stress. Thus, under dynamic loading, aluminum foams can be used for …

Changing the Choice of Materials - Battery Housings Made of Steel

  • Guest Commentary

Sustainable Battery Protection Housing from Integrative Materials

  • Cover Story

Designing a crashworthy battery enclosure for a battery electric vehicle presents engineering teams with manifold challenges. The housing must be lightweight while providing reliable crash protection. Achieving this in an environmentally friendly …

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    Image Credits
    Aluminum foam battery case/© Fraunhofer IWU , in-adhesives, MKVS, Ecoclean/© Ecoclean, Hellmich GmbH/© Hellmich GmbH, Krahn Ceramics/© Krahn Ceramics, Kisling AG/© Kisling AG, ECHTERHAGE HOLDING GMBH&CO.KG - VSE