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Thermal Runaway Simulation

Evaluate Thermal Runaway Risks Before They Compromise Battery Safety

Thermal runaway is a rapid and uncontrolled increase in temperature that can occur when heat generated within a battery exceeds its ability to dissipate that heat. Once initiated, this process can propagate from one cell to adjacent cells, potentially leading to severe safety incidents, reduced battery performance, and permanent system failure. Thermal Runaway Simulation enables engineers to evaluate these risks before product development, testing, or commercial deployment.

At Experiqs, we perform Thermal Runaway Simulations to analyze heat generation, temperature propagation, cell-to-cell interactions, and thermal behaviour under abnormal operating conditions. These simulations help engineers assess battery safety, optimize thermal protection strategies, and validate battery system designs across electric mobility, energy storage, aerospace, and industrial applications.

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Thermal Runaway Simulation
Thermal Runaway Simulation 2

Why Thermal Runaway Simulation Matters

As battery systems become larger and more energy-dense, preventing thermal runaway has become a critical design requirement. Factors such as internal short circuits, mechanical damage, overcharging, manufacturing defects, or inadequate cooling can initiate thermal runaway, resulting in rapid heat propagation and system failure.

Thermal Runaway Simulation enables engineers to investigate these scenarios during the design stage. By evaluating heat propagation, temperature evolution, and the effectiveness of thermal protection measures, engineering teams can improve battery safety, optimize cooling strategies, and support compliance with safety requirements while reducing dependence on destructive physical testing.

Our Capabilities

Our thermal runaway simulation capabilities support the evaluation of abnormal thermal events across battery cells, modules, and complete battery packs. These analyses help engineers investigate heat propagation, assess thermal containment strategies, improve battery safety, and validate engineering designs before deployment.

Simulation capabilities include:

Thermal Runaway Initiation Analysis

Cell-to-Cell Heat Propagation Evaluation

Battery Pack Temperature Analysis

Thermal Containment Assessment

Cooling System Performance Evaluation

Thermal Barrier Effectiveness Studies

Battery Safety Validation

Thermal Protection Design Optimization

Applications

Thermal Runaway Simulations are widely applied across electric vehicles, battery energy storage systems (BESS), consumer electronics, aerospace, marine systems, industrial equipment, renewable energy storage, medical devices, and portable power systems where battery safety and thermal reliability are critical.

Deliverables

Depending on the project requirements, clients may receive:

  • Simulation report
  • Temperature propagation analysis
  • Thermal contour plots
  • Cell-to-cell heat transfer visualization
  • Battery safety assessment
  • Thermal protection performance evaluation
  • Engineering recommendations for design optimization
  • Validation results, where applicable

Talk to Our Engineering Team

Whether you’re evaluating battery safety, investigating thermal runaway propagation, optimizing thermal protection systems, or validating battery designs under abnormal operating conditions, our engineers can help identify the appropriate thermal runaway simulation approach for your application.

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Thermal Runaway Simulation 3

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Let’s Start an R&D Discussion

Whether you’re exploring a new R&D initiative, seeking advanced simulations, planning experimental validation, or evaluating product feasibility—our experts are ready to assist you.

Let’s Start an R&D Discussion

Whether you’re exploring a new R&D initiative, seeking advanced simulations, planning experimental validation, or evaluating product feasibility—our experts are ready to assist you.