Boyd Opens State-of-the-Art Battery Material Test Lab to Accelerate EV Innovation and Safety
Boyd, a global leader in battery safety solutions and a pioneer in thermal runaway containment and thermal propagation prevention technologies, has officially announced the grand opening of its advanced Battery Material Safety Laboratory located in San Jose, California. This new facility marks a significant milestone for Boyd as it continues to lead the charge in improving the safety, performance, and development speed of electric vehicle (EV) batteries.
With a reputation for innovation in thermal management systems, Boyd’s new lab is designed to support the rapidly evolving electric mobility industry by enabling faster, more accurate testing of battery materials. By consolidating all major testing capabilities into one fully equipped location, Boyd offers EV manufacturers and battery developers an all-in-one solution for evaluating and validating materials used in next-generation battery packs.
A New Standard in Battery Safety Testing
The San Jose Battery Material Safety Lab is more than just a testing facility—it represents a comprehensive ecosystem for battery material validation. Designed from the ground up to meet the stringent requirements of the world’s most prominent battery manufacturers and electric vehicle OEMs, the lab is equipped with state-of-the-art tools and staffed by experts in materials science, thermal engineering, and safety systems.
Boyd’s in-house testing capabilities include a broad array of performance evaluations. These tests measure material behavior under extreme and varied conditions, simulating real-world thermal, mechanical, and environmental stressors that EV batteries experience over their lifecycle. The lab supports testing for key parameters such as:
- Hot side and cold side thermal exposure
- Torch and grit resistance
- Thermal conductivity and heat dissipation
- Moisture and water ingress resistance
- Compression force deflection (CFD)
- Dielectric strength and electrical insulation
All of these tests are designed to deliver high-quality data that allows EV brands to make informed, confident decisions about the materials they use to protect against thermal propagation events and improve overall battery safety.
Meeting the Demands of the EV Industry
Battery design and innovation in the EV industry are progressing at an unprecedented pace, but the speed of product development is often constrained by the time-consuming and complex process of material validation. Boyd’s new lab directly addresses this bottleneck by enabling manufacturers to quickly test and validate the performance of different material combinations under simulated real-world conditions.
By combining testing, analysis, and material expertise under one roof, Boyd significantly shortens the development cycle for electric vehicle batteries. The facility not only delivers reliable test results faster but also supports iterative development, allowing for immediate feedback and adjustment of materials or designs based on test outcomes.
Boyd’s holistic approach ensures that every aspect of battery material safety—from thermal shielding and insulation to flame resistance and structural integrity—is rigorously tested to meet the industry’s most demanding standards. This enables customers to validate their solutions quickly and with greater confidence in their performance, durability, and safety under extreme operating conditions.
Simulation-Driven Design and Predictive Modeling
In addition to physical testing, Boyd’s Battery Material Safety Lab is integrated with powerful simulation capabilities. The company’s engineering teams use advanced proprietary finite element analysis (FEA) software to model thermal runaway events and material responses, allowing customers to explore a variety of design and material combinations before physical prototyping even begins.
This predictive modeling approach helps reduce the number of physical iterations required during development, saving both time and resources. Boyd’s simulations are calibrated using real-world data collected from in-lab tests, ensuring a high degree of accuracy and correlation between predicted and actual material performance.
By combining simulation with rapid prototyping and in-house manufacturing capabilities, Boyd is uniquely positioned to provide a closed-loop development cycle. This means that from initial design and simulation to material testing and final production, customers can work with a single partner to streamline their EV battery development process.
Accelerating Time-to-Market
One of the most significant benefits of Boyd’s new facility is its ability to compress the traditionally lengthy and fragmented process of battery material validation. In the past, manufacturers would have to coordinate with multiple vendors and test labs to complete all necessary evaluations, often adding weeks or months to their timelines.
With the opening of the Battery Material Safety Lab, Boyd provides a centralized, one-stop-shop solution. This enables faster testing cycles, immediate engineering feedback, and the ability to transition directly into scaled production—all from the same trusted partner. The result is a dramatically shortened time-to-market, enabling companies to launch new EV products more quickly while maintaining the highest levels of safety and compliance.
Commitment to Safety and Innovation
Speaking at the launch of the lab, Michael Sutsko, President of Boyd’s Engineered Materials Division, shared the significance of this development in the broader context of the electric mobility transformation.
“We are excited to unveil our new state-of-the-art Battery Material Safety Lab,” said Sutsko. “Battery material validation is critical to EV safety and has traditionally been difficult to complete. We are helping our customers accelerate battery design and time-to-market cycles as a one-stop-shop to design, validate, and manufacture integrated thermal runaway prevention technologies.”
Sutsko emphasized that Boyd’s investment in this advanced testing lab is part of the company’s ongoing commitment to innovation, sustainability, and safety in the transportation sector. As the global transition to electric vehicles gains momentum, ensuring the safety and efficiency of battery systems has become more critical than ever.
A Strategic Location and Vision for the Future
Situated in the heart of Silicon Valley, Boyd’s San Jose lab is strategically positioned to serve leading automotive OEMs, battery developers, and clean technology innovators across North America and beyond. The location offers easy access to major technology hubs and manufacturing centers, fostering close collaboration and real-time communication between Boyd and its customers.
Looking ahead, Boyd plans to continue expanding its material science capabilities and battery safety offerings. The company sees this new lab as a cornerstone of its broader vision to enable safer, more reliable electric vehicles that can perform in even the most demanding conditions.
As electric vehicles become the cornerstone of global transportation, the need for advanced battery safety technologies will only grow. With its new Battery Material Safety Lab, Boyd is not only meeting today’s needs but paving the way for the safer, faster, and more efficient EVs of tomorrow.
