BorgWarner has secured a contract with an unnamed major North American OEM to supply an 800 V integrated drive module (iDM) and a generator module with a dual inverter. The components will be used in a series of the automaker’s extended-range electric vehicle (EREV) trucks and large-frame SUVs, with production set to begin in 2029.
The iDM is a two-in-one unit combining an induction e-machine with a gearbox. BorgWarner chose an induction motor rather than a permanent magnet design, which the company says eliminates rare-earth magnet dependency and supports a more resilient supply chain. The generator module pairs a permanent magnet electric machine with the dual inverter, mounted directly to the internal combustion engine to extend the vehicle’s electric range.
A key design challenge was fitting the drive components into packaging space shared with the ICE. BorgWarner says it achieved the required power and torque targets in a compact form factor using its torque-dense induction machine for the iDM and its next-generation Viper power module technology in the dual inverter, which the company describes as an “extremely power-dense” design that enabled a smaller, more cost-effective package.
“This business win showcases our breadth in the propulsion space in North America,” said VP Stefan Demmerle, “from platform-based, high-performing and efficient drive units to inverters, e-machines, control boards and more.”
Xos has unveiled its 2026 model year Class 6 strip chassis at a starting price of $99,000, which the company calls the most competitive price point in the commercial EV segment.
The 23,000 lb GVWR chassis is purpose-built for return-to-base fleet operations, offering approximately 120 miles of range on the standard configuration and up to 200 miles on the extended-range variant. It uses an LFP battery system rated for 4,000+ charge cycles. The platform features industry-standard axles, wheel ends and suspension, which Xos says enables nationwide service capability through existing supply chains rather than proprietary components.
The 2026 model adds enhanced over-the-air update capability for remote performance optimization, charging strategy updates and predictive maintenance without vehicle downtime.
“We’re not the newest entrant making promises, we’re a proven leader delivering results today,” said CEO Dakota Semler. “At a $99,000 starting price, we’re making commercial electrification accessible at scale.”
Xos says it has more than 1,000 vehicles and powertrains on the road, manufactured at its Tennessee factory, with fleet customers including UPS, FedEx, Cintas and Loomis. The chassis comes with a minimum three-year warranty.
EV charging providers don’t seem to have gotten the memo about the demise of EVs—they’ve been deploying new chargers in record numbers in the US and Europe. Retail chains also seem to be ignoring the steady drumbeat of doom—Walmart, Kroger, Wawa and others are planning to open thousands of new charging locations over the next few years.
However, EV charging provider ChargePoint predicts that even these numbers of public chargers won’t be adequate. The company has revealed data insights from more than 100 million EV charging sessions enabled in the last year. This data, combined with 2025 EV sales figures, suggests that the availability of public charging infrastructure is not keeping up with driver demand.
ChargePoint’s data shows notable growth in both charging port expansion and utilization across its network, and indicates that the number of EVs on the road is growing faster than the volume of public charging infrastructure needed to support them.
“ChargePoint believes we have entered the next phase of EV adoption,” said CEO Rick Wilmer. “Nearly 60% of the 19.3 billion electric miles we’ve enabled in nearly 18 years took place over the most recent two years. New EV sales are no longer the primary benchmark for charger demand, it is the total number of EVs on the road. Those installing chargers in 2026 should see accelerated ROI because of this utilization pressure.”
ChargePoint cites auto industry data showing that global EV sales increased 20% in 2025. Whether charging demand is evaluated by volume or utilization, the data shows that the number of charging sessions is outpacing new charger installations. In 2025, the volume of charging sessions increased by 34%, despite a much smaller increase in the number of vehicles on the road. Even as 190,000 more charging ports became available to drivers on the ChargePoint network, charger utilization still outpaced the growth of new ports by almost 20%. This bottleneck may get worse in 2026 unless the rate of charger installation increases, the company says.
Karma Automotive and solid-state battery developer Factorial have announced what they describe as the first solid-state battery production program in the US for passenger vehicles. Factorial’s FEST (Factorial Electrolyte System Technology) cells will be integrated into Karma’s next-generation vehicle platform, starting with the all-electric Kaveya super-coupe—a 1,000+ hp vehicle with a top speed exceeding 200 mph, scheduled for late 2027.
Karma had originally planned an earlier launch for the Kaveya but delayed it in 2025. “We did not yet see a clear path to fully delivering the uncompromising driving experience that should be expected from an American ultra-luxury vehicle company,” said CEO Marques McCammon. “Now through the partnership with Factorial and the integration of FEST, we can not only deliver that experience, but also open a pathway to stronger, more stable electrified drive systems.”
A notable aspect of Factorial’s technology is its manufacturing compatibility. According to the company, FEST cells can be produced using up to 80 percent of existing lithium-ion manufacturing equipment, rather than requiring entirely new production lines. Factorial says this enables rapid scale-up of the production program with Karma.
“FEST was built to scale,” said Factorial CEO Siyu Huang. “This milestone not only highlights the energy and performance solid-state technology can deliver but also underscores the global leadership of US technology innovators.”
Factorial’s other automotive partners include Mercedes-Benz, Stellantis, Hyundai and Kia.
US-based lithium-ion battery fire extinguishing products manufacturer Full Circle Lithium has launched six new lithium-ion fire extinguisher sizes, initially in North American markets.
The extinguishers include four retail-focused models—20 ounces, 1 litre, 2 litres and 3 litres—and two industrial-size units—30 litres and 50 litres—designed to address the risks associated with lithium-ion battery use across residential, recreational and industrial environments.
The new products will use FCL-X, the company’s non-hazardous, non-toxic, water-based fire-extinguishing agent.
The retail-focused models are designed for homeowners and consumer applications, providing targeted protection for electronics, laptops, e-bikes, e-scooters, power tools and other battery-powered devices commonly found in the home. The compact units are designed for easy placement in garages, living spaces, workshops and charging areas.
The new extinguishers also address the expanding use of lithium-ion batteries in recreational applications, including golf, boating and powersports.
The two industrial-size extinguishers deliver greater agent capacity and performance, making them well-suited to higher-risk and commercial environments such as warehouses, service facilities, charging stations and industrial operations that manage large quantities of lithium-ion batteries. A 100-litre format will also be available over the next few months.
All six extinguisher sizes are engineered to meet applicable safety and performance standards and are available immediately through FCL’s authorized distribution network. They will also soon be listed on FCL’s website.
“Lithium-ion batteries are everywhere, and the fire risks they present are fundamentally different from traditional fires,” said Chad Carver, VP of Sales and Operations at FCL. “These new extinguishers were developed to help protect people, property, and investments, whether that’s a family home, a golf cart fleet, a boat at the marina, or an industrial facility.”
US-based Ionic Mineral Technologies has expanded the lease rights for its Silicon Ridge rare earth project in Utah and completed a strategic step-out drilling program for its Preliminary Economic Assessment (PEA).
The 4,100 additional acres of land consolidate the company’s strategic land package to roughly 13,000 contiguous acres. The expansion is strategically significant, as it facilitates direct, optimized logistical access from the project area to Ionic’s processing facility in Provo.
The drilling program was designed to test the lateral extent of the mineralized clay system and provide the data necessary to expand the geological model for the PEA. Each step-out hole intersected the targeted mineralization and ended within the mineralized formation, confirming the system’s strong lateral continuity and indicating it remains open at depth, the company said.
Silicon Ridge’s polymetallic clay will be the primary feedstock for Ionic vertically integrated production, designed to bypass complex, high-cost hard-rock processing.
The company intends to provide a domestic source of minor metals and rare earths from its IAC-Plus system, which contains gallium, germanium, rubidium, cesium, scandium, lithium, vanadium, tungsten and niobium. The company also plans to produce its IonAl alumina for industrial applications and Ionisil Nano-Silicon anode material for lithium-ion batteries.
“Consolidating 13,000 acres and confirming continuous mineralization across a 1,400-acre footprint reinforces that Silicon Ridge has the potential to be one of North America’s most significant and scalable critical mineral assets,” said Andre Zeitoun, CEO and founder of Ionic Mineral Technologies.
Continued optimization of battery design means addressing thermal runaway and other issues. Pressure-sensitive adhesive (PSA) tapes may be an important part of the solution.
By Max VanRaaphorst, Market Manager, Energy Storage, Avery Dennison
This is a dynamic time for the electric vehicle marketplace. According to an April 2025 report by Cox Automotive, EV sales rose 11.4% in the first quarter of 2025 compared to the first quarter of 2024. Many long-term forecasts predict continued double-digit growth.
The near-term outlook for the industry, however, is volatility. As of this writing, the Trump administration’s tariff plan remains in flux. Whatever their final form, tariffs seem likely to stir the global supply chains that manufacturers depend on.
Regardless, engineers tasked with making EV batteries safer, more durable, and more energy-dense must remain focused on the task at hand. Truly transformative technologies, such as solid-state batteries, are still years off. So, continued progress means further optimization of current technology platforms. Pressure-sensitive adhesive (PSA) tapes, integrated with functional materials, are a versatile, easy-to-use, and cost-effective material solution for many of today’s EV battery engineering challenges.
The thermal management ecosystem
A key challenge in this story of optimization is that of thermal management.
A battery is a complex ecosystem requiring temperature regulation for optimal cell performance during normal use as well as during extreme events. At the most basic level, that means cells should be warmed when they’re too cold and cooled when they’re too warm.
Batteries thus have three types of thermal requirements:
Thermal insulation Low thermally conductive (insulating) materials are used to protect normally operating cells from overheating, thus preventing thermal runaway events.
Thermal conductivity High thermally conductive materials, such as thermal interface materials (TIMs), are used to connect cells to cooling components and facilitate heat transfer.
Venting
Venting strategies allow hot gases to escape a malfunctioning cell while protecting adjacent cells. These strategies can incorporate various thermal materials.
To understand thermal conductivity … go for a hike in the woods
Compare the idea of thermal conductivity to a hike in the woods. Imagine trying to bushwhack through a dense forest of trees, low-lying scrub, roots and rocks, and perhaps some mud. It’s difficult, you’re breathing hard, sweating and maybe cursing a bit! Now compare that to a walk on a flat, well-maintained, tree-lined trail. It’s easier and probably more enjoyable. From heat’s perspective, a low conductivity material is like that dense forest — difficult to traverse. A high conductivity material is the gentle trail.
Another important consideration is the length of the hike itself. A short hike through a dense forest may not be much of an obstacle. It’s the long slog that ultimately slows you down.
That brings us to PSA tape solutions for thermal management. Tapes, by design, are very thin. So while they don’t tend to offer high thermal conductivity, they do offer just a short path for heat to travel. But due to their tremendous versatility, tapes can also be integrated with low thermal conductivity materials, thus making them suitable for a wide range of thermal management applications within a battery pack.
Thermal runaway barrier solutions
Thermal runaway starts when an overheating cell combusts. That fire grows to the point at which hot gases and materials burst from the cell. The escaping matter causes other cells to overheat, catch fire and burst in turn. A module-level thermal runaway event can then spread to other modules in a pack, causing complete destruction of the battery pack and likely the vehicle.
Tapes can be used to encapsulate insulating (low heat conductivity) barrier materials, such as mica, ceramic paper or aerogels. These can then be placed between cells, modules, and/or on the inside of the pack lid. Because of tapes’ thin profiles, they’re an ideal choice for these narrow spaces — providing the necessary bond while allowing for the maximum possible thickness of the insulating material given the space constraints.
In some circumstances, these PSA-based solutions can prevent cell- or module-level thermal runaway propagation. But in most cases, they can at least slow the spread of thermal runaway, providing valuable time for passengers to exit the vehicle.
Thermal runaway venting solutions
As noted above, thermal runaway is underway when hot gases and materials erupt from a single cell. Cell manufacturers thus integrate venting strategies into their designs.
A vent is simply a port that allows hot, expanding gases and burning material to escape the cell’s confines, creating a more controlled pressure release. The problem lies in the fact that as those escaped rush through the module, they can infiltrate other cells through their vent ports, and thus initiate a thermal runaway event.
What’s needed is a venting strategy that allows that pressure release while protecting healthy cells from those hot gases and materials. Again, PSA tapes offer an elegant solution: In this case, it’s tapes with an anisotropic carrier—just one side of the tape offers flame resistance.
These PSA tapes are applied to battery cells during assembly, covering the vent ports. The anisotropic carrier then allows flames to escape through the port of a burning cell. But as the flames then circulate through the module, the flame-retardant side of the tape protects the vent ports of healthy cells.
PSA-based anisotropic tapes can help protect healthy cells and inhibit thermal runaway.
Flame retardance isn’t permanent. Eventually, the tape is compromised, and flames can affect healthy cells. But again, this is about mitigating and delaying full thermal runaway, and giving passengers valuable time for a safe escape.
Dielectric protection solutions
Electrical arcing in a high-voltage environment can often lead to fire, and thus is another issue that can affect a battery ecosystem’s thermal management. Again, PSA tapes are stepping up to the challenge.
Polymer film tapes can be used within the pack and module for bonding or to encapsulate critical parts. These tapes offer high dielectric strength per unit thickness and tend to inhibit heat flow, making them a preferred alternative to many traditional dielectric coatings.
A new PSA tape technology is a dielectric tape that can be applied to flat metal blanks prior to stamping and forming. It’s an easy-to-use solution that optimizes both dielectric strength and assembly flows, as it eliminates curing and cleaning, and other processes needed for traditional coatings. Avery Dennison has recently published a whitepaper explaining how stampable dielectric PSA tape technology can benefit manufacturers.
PSA tape solutions are available now
All of the PSA tape solutions discussed in this article are currently available. In fact, the Avery Dennison EV Battery Portfolio contains a wide range of PSA tape-based solutions engineered to help manufacturers address issues such as thermal runaway and dielectric protection. And these tapes are easy to incorporate into either manual or automated assembly processes, helping EV battery manufacturers optimize both workflow and design.
Tape solutions can be cut and stamped to spec and provided at scale by local converters. These third-party providers work closely with Avery Dennison and the battery manufacturer to ensure the right solutions are provided at the volumes needed, even in a volatile time for the automotive industry.
A bright future for EVs
Whatever volatility the near term might hold, the future is bright for EVs. By using solutions such as PSA tapes, manufacturers can be confident their products will meet consumers’ needs for safety, reliability and durability.
