Irving-based Alkegen, a supplier of battery cell spacers, has announced the full-scale commercial production of its proprietary fiber-enhanced aerogel insulation for electric vehicle (EV) battery fire protection.
“We’ve taken a platform that’s already proven itself in the industrial space and scaled it for one of the fastest-growing markets in the world—EV battery safety,” Alkegen CEO John Dandolph said in a statement. “Automakers no longer have to rely on a single supplier in North America for this mission-critical solution.”
Alkegen relocated its headquarters from Tonawanda, New York, to Irving in January 2022.
Follows announcement of Jaguar Land Rover partnership
In April 2024, Alkegen announced a partnership with Jaguar Land Rover to provide its new line of anti-thermal propagation products, which are intended to prevent the spread of thermal runaway within EV battery packs.
The company said its newly announced launch marks its strategic product portfolio expansion for the EV market, delivering a comprehensive portfolio of advanced thermal and electrical insulation materials for original equipment manufacturers. With the addition of aerogels to its offering, Alkegen said it now provides OEMs with end-to-end insulation solutions optimized for performance, design flexibility, and scalable production.
Alkegen’s AlkeGel product [Photo: Alkegen]
AlkeGel offers ‘ultra-thin, safe, and easy-to-install thermal runaway protection’
AlkeGel, Alkegen’s next-generation, high performance fiber-aerogel composite, is engineered to meet OEM demand for ultra-thin, safe, and easy-to-install thermal runaway protection for lithium-ion battery systems, the company said. Unlike traditional aerogels, AlkeGel is low-dust, eliminating the need for full encapsulation and allowing for simpler and more cost-effective part designs that integrate more easily into space-constrained EV battery packs, Alkegen added.
“Automakers need reliable, scalable partners. With AlkeGel, they now have a superior choice,” Chief Technology Officer Chad Cannan said in a statement. “AlkeGel has proven to be significantly less dusty than traditional aerogel insulations—making it easier to convert, safer to handle, and more adaptable to complex part geometries.”
With the addition of aerogels, Alkegen said it is building on its leadership in cell spacer technology to offer a full insulation portfolio—including wraps and thermal barriers—giving EV manufacturers the flexibility to match material to application.
“The EV industry has been waiting for a credible second source of battery fire protection aerogel insulation in North America,” said Marty Melhorn, president, Battery Pack and Advanced Mobility at Alkegen. “AlkeGel is here. We’re manufacturing at scale—and we’re just getting started.”
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