Welcome to the 7th Annual Battery Thermal Management USA 2025, CA. The premier technical summit dedicated to the future of battery thermal engineering and full-system integration for next-generation electric vehicles.This highly focused gathering brings together the brightest minds in battery innovation, thermal strategies, and EV system architecture to push the boundaries of what’s possible in high-performance, high-efficiency battery design.

Taking place in Palo Alto, California, on May 29, 2025, this OEM-led, content-driven event delivers a meticulously researched agenda, developed in collaboration with automakers, tier-one suppliers, and breakthrough technology providers to address today’s challenges and tomorrow’s innovations.

At BTM USA 2025, we go beyond conventional cooling strategies to explore next-generation thermal management, where the focus is on:

Full-system thermal integration – optimizing cell, pack, and vehicle-level temperature control

Advanced cooling architectures – from integrated cooling loops to thermal-energy harvesting

Predictive thermal management – leveraging smart control algorithms and digital twins

Megawatt charging compatibility – overcoming high-power density and thermal stability challenges

Structural battery packs & cell-to-pack innovation – unlocking new levels of energy density and safety

This is not just another industry conference. BTM USA 2025 is where engineers, innovators, and OEMs come together to solve real-world technical challenges and develop the next wave of electrification strategies.

The Next Wave of Thermal Integration

Join over 500 senior BEV engineers, system architects, and industry visionaries as they engage in a solutions-driven, highly technical environment, sharing knowledge on scaling high-efficiency, safe, and cost-effective battery thermal systems.

On the exhibit floor, experience live demonstrations and explore cutting-edge technologies from industry-leading suppliers and disruptors.

With the industry moving at an unprecedented pace, this is your chance to be part of the conversations that will shape the future of electrification. Don’t miss the opportunity to connect with the leaders driving system-level innovation, see groundbreaking solutions firsthand, and gain exclusive insights into the next era of battery thermal management.

Full-System Thermal Integration: Unlocking Safe, Fast, and Scalable Energy Management for Next-Gen xEV Platforms

With higher power densities, structural battery designs, and megawatt charging, thermal management must advance beyond isolated cooling strategies. Discussions will explore integrated thermal ecosystems, where vehicle architecture, cell design, and pack layout converge to enhance safety, performance, and manufacturability.

Next-Generation Battery Architectures: Engineering for Energy Density, Safety, and Performance

Advancements in solid-state batteries, silicon anodes, and novel cathode materials are revolutionizing battery technology. Key topics include cell design for improved thermal performance, manufacturability considerations, and integration challenges in next-gen xEV platforms.

Advancements in Battery Pack Design and Integration

Modular configurations, cell-to-pack and cell-to-chassis technologies, and novel safety enhancements are reshaping energy storage and thermal efficiency. Discussions will highlight high-power battery integration, scalable pack designs, and thermal considerations for ultra-fast charging applications.

Battery Thermal Management Systems: Beyond Cooling to Full-System Optimization

Thermal management is evolving into predictive, AI-driven temperature control that enhances charging speed, efficiency, and safety. Topics include liquid cooling advancements, phase change materials, smart control strategies, and preventing thermal runaway

Scaling Battery Swapping for xEVs: Overcoming Thermal Management and Grid Integration Challenges

Battery swapping presents unique challenges in thermal regulation, bidirectional power flow, and scalability. Experts will explore temperature control in high-cycle battery swaps, decentralized energy storage models, and grid impact strategies.

Rethinking Thermal Management: Integrated Protection and Performance for BMS Electronics

As high-power battery management systems (BMS) demand greater reliability, new strategies are emerging for PCB protection, heat dissipation, and material innovations. Discussions will examine thermal interface materials (TIMs), hybrid material solutions, and scalable manufacturing approaches.

Innovations in Battery Assembly Processes: Advanced Manufacturing for Performance and Reliability

Cutting-edge battery manufacturing is driving improvements in precision welding, automated assembly, and AI-powered quality control. Sessions will explore robotic integration, advanced joining techniques, and scalable production methods that optimize pack efficiency.

Sustainability in Battery Materials and Recycling: Circular Economy Strategies for Next-Gen Batteries

With growing environmental concerns, the focus is on eco-friendly materials, efficient recycling processes, and second-life applications. Key discussions include innovations in material sourcing, lifecycle assessment, and closed-loop battery manufacturing.

Battery Data and Diagnostics: Standardization and Predictive Analytics for System Optimization

Standardizing battery data formats and diagnostic protocols is crucial for BMS accuracy, safety monitoring, and predictive maintenance. Topics include real-time battery health tracking, AI-driven failure detection, and interoperability in battery management systems.

AI and Machine Learning in Battery Technology: Driving Intelligent Optimization and Performance Gains

Machine learning is transforming battery lifecycle management, charging efficiency, and predictive maintenance. Discussions will focus on AI-driven failure detection, self-optimizing battery systems, and neural network applications in battery chemistry analysis.

Advanced 3D Modeling and Simulation for Battery Design

Virtual simulations are reshaping battery design, thermal performance validation, and safety modeling. Experts will cover CFD analysis, electrothermal simulations, and predictive modeling for next-gen battery systems.

Cybersecurity in Battery Technology and Manufacturing

With greater connectivity in battery systems, cybersecurity has become a critical priority. Key focus areas include threat prevention in battery management systems, data protection strategies, and securing manufacturing processes against cyber risks.

Innovations in Fast Charging Technology: Scaling Up for High-Power Charging

New developments in megawatt charging, high-voltage power electronics, and thermal solutions for ultra-fast charging are shaping the future of EV infrastructure. Experts will explore scalability challenges, thermal stress mitigation, and charging efficiency optimization.

Bridging Cell-Level Data with System-Level Insights: A New Path for Battery Thermal Management

A deeper understanding of energy loss, heat generation, and charge-transfer kinetics is enabling more precise thermal control. Discussions will cover data-driven approaches to battery pack heat management and performance optimization across different chemistries.

Immersion Cooling as a Paradigm Shift in High-Power BTM for Extreme Duty Applications

With fast charging and high-power cycles pushing conventional cooling limits, immersion cooling is gaining traction. Topics include fluid selection, system scalability, thermal efficiency, and regulatory considerations.

Optimizing EV Battery Design with Digital Twins

Digital twin technology is enabling predictive modeling of thermal performance, charging behavior, and aging effects. Key discussions include multi-scale simulation techniques, real-time diagnostics, and AI-driven predictive maintenance.

Holistic Integration: How Standardized Coolant Modules Are Transforming EV Thermal Systems

The shift from component-based cooling systems to fully integrated modular solutions is streamlining packaging efficiency, weight reduction, and system reliability. Experts will explore next-generation thermal module designs and their impact on manufacturability.

Smarter Heat Management: How Integrated Systems and PCMs Are Reshaping EV Performance

By integrating phase change materials (PCMs) and thermal buffers, energy recovery and system-wide temperature control can be optimized. Discussions will focus on PCM applications in fast-charging, power management, and vehicle-wide thermal coupling.

Beyond Lithium-Ion: Addressing the Unique Thermal Challenges of Solid-State Batteries

Solid-state batteries introduce new heat generation and dissipation challenges, requiring advanced cooling strategies. Key topics include thermal runaway prevention, AI-driven thermal management, and novel materials for next-gen battery systems.

Pushing the Boundaries of Battery Systems with Data-Driven, Temperature-Controlled Charging and Power Delivery

Traditional fast-charging approaches restrict power delivery to prevent overheating. Experts will discuss how real-time, in-situ diagnostics and model-free control strategies are optimizing charging speed and thermal stability.

Unifying Innovation: Integrating Safety, Efficiency, and Scalability in xEV Battery Thermal Management

As EV technology advances, thermal management is no longer just about cooling—it’s about system-wide orchestration. Discussions will highlight the future of xEV thermal ecosystems, from safety and efficiency to mass-market scalability.

Battery Thermal Management Solutions

• Liquid cooling technologies (direct & indirect cooling solutions)
• Immersion cooling systems for high-power battery applications
• Phase change materials (PCMs) for heat absorption and dissipation
• Thermal interface materials (TIMs) for improved conductivity
• Smart active thermal management systems (AI-driven cooling strategies)
• Heat sinks, cold plates, and advanced heat spreaders
• Next-generation coolants and nano-fluid thermal solutions
• High-efficiency cooling pumps, valves, and flow control systems
• Fire-resistant materials for battery enclosures
• Advanced thermal coatings and insulation materials

Battery Pack and Module Design

• Structural battery pack solutions for high-energy-density systems
• Cell-to-pack (CTP) and cell-to-chassis (CTC) integration technologies
• Lightweight composite enclosures and high-strength materials
• Thermally optimized battery pack designs for enhanced efficiency
• Modular battery packs for flexible and scalable applications
• Crash-resistant battery enclosures and impact mitigation solutions
• Fire suppression materials and anti-propagation barriers
• Sealing, gasketing, and vibration-damping solutions

Battery Cell Innovations & Advanced Materials

• Solid-stte battery technology providers
• Silicon anodes and next-generation anode materials
• High-performance cathode materials (NMC, LFP, LFMP, etc.)
• Advanced electrolyte solutions (solid-state, ionic liquid, and hybrid)
• Graphene-enhanced battery materials for improved conductivity
• Next-gen separator materials for higher safety and performance
• Sodium-ion and alternative battery chemistries
• Eco-friendly and sustainable battery materials
• Battery material suppliers specializing in recyclability

Battery Assembly and Manufacturing Solutions

• Automated battery pack assembly lines
• Laser welding and precision joining systems
• Ultrasonic welding and resistance welding for battery cells
• Robotic automation for high-speed battery production
• Coating and encapsulation solutions for battery safety
• Adhesive bonding solutions for battery module integration
• 3D printing and additive manufacturing for battery components
• Smart factory and gigafactory automation solutions

Battery Safety and Protection Systems

• Gas sensing and off-gassing detection solutions
• Real-time battery failure monitoring systems
• Fire suppression and containment technologies
• Short-circuit and overvoltage protection components
• Thermal runaway prevention materials and solutions
• Vibration-resistant battery packaging solutions
• Advanced safety coatings and insulation for high-voltage batteries

Battery Management Systems (BMS) and Cloud-Based Monitoring

• AI-driven predictive maintenance and failure detection
• Cloud-based battery diagnostics and real-time monitoring platforms
• Wireless battery management systems (wBMS)
• State-of-health (SoH) and state-of-charge (SoC) optimization tools
• Machine learning-based battery analytics solutions
• Embedded BMS software and firmware developers
• Cybersecurity solutions for connected battery management systems

Power Electronics & Energy Management Solutions

• High-voltage inverters and converters for battery applications
• DC-DC power conversion technologies
• Silicon carbide (SiC) and gallium nitride (GaN) power semiconductors
• Advanced battery switching and protection devices
• High-efficiency energy storage solutions
• Power electronics cooling solutions for fast charging
• Smart power management solutions for EV battery efficiency

Fast Charging & Next-Generation Charging Infrastructure

• Megawatt and ultra-fast charging solutions
• Wireless and inductive EV charging technologies
• Bidirectional charging (V2G, V2H, V2X) systems
• Liquid-cooled charging cables and connectors
• Smart grid-integrated EV charging solutions
• Next-generation battery swap stations and modular energy solutions
• Energy management platforms for fast-charging infrastructure

Digital Twin, AI, and Advanced Simulation Tools

• Cloud-based battery simulation platforms
• AI-driven battery modeling and predictive analytics
• 3D modeling and CFD simulations for battery performance optimization
• Electrochemical impedance spectroscopy (EIS) testing
• Battery failure prediction algorithms using AI/ML
• Data-driven battery lifecycle assessment tools

Battery Recycling and Second-Life Applications

• End-of-life battery disassembly and recycling solutions
• Automated battery sorting and repurposing technology
• Second-life energy storage developers
• Hydrometallurgical and pyrometallurgical recycling
• Sustainable logistics for battery collection and reprocessing
• AI-driven battery health assessment for second-life applications
• Battery circular economy solutions and material recovery technologies

Cybersecurity for Battery Systems and Manufacturing

• Secure battery communication protocols
• Data encryption and threat detection for BMS and cloud platforms
• Intrusion detection systems for battery management networks
• Blockchain-based battery data security solutions
• Cyber-resilient cloud computing for battery diagnostics
• AI-driven cybersecurity solutions for EV battery operations

Advanced Inspection and Testing Technologies

• AI-powered automated battery inspection systems
• Defect detection using computer vision and ML
• Battery safety and abuse testing equipment
• Multi-physics simulation tools for battery pack validation
• Non-destructive testing (NDT) for high-voltage batteries
• X-ray and ultrasonic inspection solutions for battery defects

Structural Integration & Lightweighting Solutions

• Multi-functional battery enclosures with integrated cooling
• Crash-resistant materials for battery pack safety
• Hybrid composite materials for lightweight battery packs
• Smart thermal protection coatings for structural integration
• Low-density, high-strength materials for battery casings

Immersion Cooling & Advanced Heat Transfer Technologies

• Dielectric fluids for direct immersion battery cooling
• Advanced conductive polymers for thermal management
• Graphene-enhanced heat transfer coatings
• Self-regulating heat dissipation materials
• High-performance liquid coolants for ultra-fast charging

Grid Integration and Energy Storage Solutions

• Grid-connected energy storage systems (BESS)
• Smart battery-enabled microgrid developers
• Vehicle-to-grid (V2G) and grid stabilization solutions
• Large-scale stationary battery storage technologies
• Home and commercial energy storage system providers

Emerging Battery Technologies & Future R&D

• High-performance energy storage for aerospace and eVTOL applications
• Next-generation hybrid battery architectures
• Battery-integrated vehicle structures for enhanced range
• Self-healing battery materials
• AI-driven chemistry development for enhanced thermal stability
• High-energy-density solid-state battery prototypes
• Quantum computing for next-generation battery modeling

Vehicle-Wide Thermal Management & HVAC Systems

• Cabin climate control systems for electric vehicles
• Smart HVAC solutions for electric vehicle efficiency
• Powertrain cooling systems for hybrid and electric vehicles
• Liquid-cooled power electronics and inverter cooling solutions
• Heat recovery and repurposing technologies for xEVs