Blue Solutions and AVL have successfully completed a collaborative evaluation program aimed at advancing safety protocols for next-generation solid-state battery cells ahead of industrial scale-up. The non-exclusive initiative combined Blue Solutions’ proprietary lithium-metal anode technology with AVL’s expertise in battery simulation, validation and safety assessment.
The partners focused on embedding safety early in the design process by conducting predictive simulations during cell scale-up and evaluating technology-specific behaviors such as internal pressure management and mechanical integrity. Advanced abuse and failure scenario modeling helped align the development with emerging regulatory requirements, including compliance with GB 38031-2025 standards under China’s New Energy Vehicle regulations.
One of the program’s key achievements was demonstrating approaches to eliminate thermal propagation—a critical challenge in high-energy-density battery systems. By integrating advanced modeling techniques, pressure-aware design and safety-first architecture, test and simulation results showed consistent safety performance even under demanding conditions.
In addition to safety validation, the program confirmed that the high volumetric energy density of the solid-state cells can be preserved without compromising safety margins. Results indicated up to a 25% increase in volumetric energy density and a 13% gain in gravimetric energy density compared to equivalent nickel-manganese-cobalt lithium-ion packs.
Olivier Caumont, Battery Systems Director at Blue Solutions, highlighted that the collaboration with AVL validated the company’s solution against the most stringent safety criteria while reinforcing its manufacturing expertise in solid-state cell and pack integration. Paul Schiffbänker, Director of Battery Development at AVL List GmbH, noted that working with the latest solid-state chemistry deepened AVL’s safety methodology capabilities and enabled the systematic integration of safety in future high-energy battery designs.
Blue Solutions and AVL plan to share detailed findings and best practices at upcoming international conferences and industry events, demonstrating their joint commitment to setting new benchmarks in scalable, inherently safe energy storage systems.
Source: Blue Solutions
