Electromobility and New Requirements for Chemical Raw Materials in the Automotive Industry: What Is Changing and How to Prepare

Photo: Marcin Jozwiak / Unsplash

Electromobility is not just a matter of propulsion, but also a fundamental transformation of the entire automotive supply chain. Manufacturers and suppliers of chemical raw materials face new challenges – from demands for high-temperature resistance of materials for batteries to lightweight composites for car bodies. At the same time, the emphasis on safety, recyclability, and compatibility with new technologies is growing. Which chemical raw materials will be essential in the coming years, and how can you prepare for these changes?

Electromobility Is Changing the Rules: Why Chemical Raw Materials Play a Key Role

The transition from internal combustion engines to electromobility is not just a matter of replacing the powertrain. The changes affect the entire vehicle design, material composition, and manufacturing processes. Chemical raw materials, which have been optimized for decades for traditional cars, now must meet entirely new requirements. For example, battery systems require special electrolytes, separators, and additives with high thermal stability and chemical resistance. Lightweight materials, such as composites or advanced polymers, are replacing metal components to compensate for the weight of batteries. This places emphasis on plastic additives, which must ensure mechanical strength, UV resistance, and long service life even under extreme conditions.

Another critical factor is safety. Electric vehicles operate at high voltages and temperatures, increasing the demands on insulating materials, coolants, and fire suppression systems. For instance, battery coolants must not only have high thermal conductivity but also low electrical conductivity to prevent short circuits. Surfactants and corrosion inhibitors in these fluids must be compatible with new materials, such as lithium-ion cells or graphite electrodes. Chemical raw material manufacturers thus face the challenge of developing products that meet strict electromobility standards, such as REACH or CLP, while remaining economically competitive.

Batteries and Powertrains: Which Chemical Raw Materials Will Determine Performance and Safety

At the heart of every electric vehicle is the battery system, whose performance and lifespan depend on the quality of the chemical raw materials used. Lithium-ion batteries dominate the market, but their further development is focused on higher energy density, faster charging, and longer service life. Electrolytes play a key role, as they must remain stable at high voltages and temperatures. Typically, mixtures of organic solvents with lithium salts are used, supplemented with additives to improve conductivity and protect against degradation. Separators, often made from polyolefins, must be porous, mechanically robust, and capable of withstanding temperatures up to 150 °C without deformation.

In addition to batteries, attention is also turning to other components of the powertrain system. For example, lubricants for electric motors must be electrically non-conductive to prevent current leakage, while also withstanding high speeds and temperatures. Lubricant additives, such as antioxidants or corrosion inhibitors, must be compatible with copper and aluminum components commonly used in electric motors. Another challenge is thermal management systems, where special coolants with low viscosity and high thermal capacity are employed. These fluids often contain corrosion inhibitors and biocides to prevent the growth of microorganisms in cooling circuits.

Photo: Marcin Jozwiak / Unsplash

Lightweight materials and additives: How to reduce weight and increase the efficiency of electric vehicles

Vehicle weight is a critical factor in electromobility, as it directly affects range and energy efficiency. Manufacturers are therefore intensively seeking ways to replace metal components with lighter alternatives without compromising strength or safety. Composite materials based on carbon fiber or glass fiber are becoming the standard for bodywork, interiors, and structural components. However, these materials require special additives such as plasticizers, stabilizers, or flame retardants to ensure their long-term durability and fire safety.

Another approach to reducing weight involves advanced polymers such as polyamides or polyurethanes, which are used to manufacture components like bumpers, dashboards, or battery covers. These materials must be resistant to mechanical stress, chemicals, and temperature fluctuations. Plastic additives, such as UV stabilizers or antistatic agents, play a key role in ensuring their long service life. For example, UV stabilizers protect polymers from degradation caused by sunlight, which is particularly important for components exposed to weather conditions. Selecting the right additives is therefore crucial for achieving the desired material properties while maintaining low weight.

How to Prepare for Changes: Practical Steps for Manufacturers and Buyers of Chemical Raw Materials

The transition to electromobility requires strategic planning and close collaboration with suppliers from manufacturers and buyers of chemical raw materials. The first step is to analyze the existing product portfolio and identify those that will be key in electromobility. For example, suppliers of surfactants, polyols, or plastic additives should consider investing in research and development of new formulations that meet the specific requirements of electric vehicles. It is also important to monitor trends in legislation, such as new requirements for material recyclability or restrictions on the use of hazardous substances under the REACH regulation.

The next step is collaboration with automobile manufacturers and their suppliers to test and certify new materials. Standard testing methods must verify whether the new chemical raw materials meet requirements for mechanical properties, thermal resistance, and long-term stability. For example, plastic additives must undergo tests for resistance to temperature cycles, UV radiation, and chemicals. Manufacturers should also consider expanding their production and storage capacities for specialized raw materials to respond quickly to market demand. Last but not least, it is important to educate customers about the benefits of new materials and assist them with their implementation into production processes.

Photo: Marcin Jozwiak / Unsplash

Thermal management in electric vehicles: Chemical innovations for safety and durability

Electric vehicles place entirely new demands on thermal management, which directly affects the safety, performance, and lifespan of batteries. While internal combustion engines used waste heat for interior heating, electric vehicles must actively regulate heat using specialized cooling fluids and heat transfer media. These fluids must meet extreme requirements: high thermal conductivity (up to 0.5 W/m·K), low viscosity at temperatures below -30 °C, and stability at temperatures above 100 °C. In addition, they must not corrode the metal components of batteries or degrade insulating materials.

Additives for cooling mixtures play a key role, such as corrosion inhibitors based on carboxylates or silicates, which protect aluminum and copper components. For batteries with high energy density, dielectric fluids with low flammability are also being developed, for example, based on esters or fluorinated compounds. These substances must be compatible with new battery cell materials, such as lithium iron phosphate (LFP) or nickel manganese cobalt (NMC) cathodes. Chemical raw material manufacturers are therefore investing in the development of mixtures that ensure uniform heat distribution and prevent local overheating.

Adhesives and Sealing Materials for High-Voltage Systems: Resistance to Electrical Stress

High-voltage systems in electric vehicles require adhesives and sealing materials with unique properties that traditional automotive applications did not encounter. Common adhesives used in car bodies or interiors are not sufficiently resistant to electric fields, which can reach values of up to 800 V. New materials must combine high dielectric strength (above 20 kV/mm), low permittivity, and resistance to partial discharges, which can degrade insulation.

For these purposes, epoxy resins with inorganic fillers such as silicon dioxide or boron nitride are used, which increase thermal conductivity and mechanical strength. Resistance to aging due to temperature cycles and chemical influences, such as electrolytes from batteries, is also important. Additionally, sealing materials must be compatible with new types of plastics and composites used for lightweight constructions. Manufacturers are focusing on fast-curing systems that enable efficient assembly in automated production lines.

Recycling and Sustainability: How Chemical Raw Materials Support the Circular Economy in the Automotive Industry

Electromobility presents not only technological but also environmental challenges, particularly in the area of battery and material recycling. Chemical raw materials play a key role in developing processes that enable efficient recovery of valuable metals such as lithium, cobalt, or nickel. Special extraction agents, such as organophosphates or chelating substances, are used for hydrometallurgical recycling methods to selectively bind metal ions from solutions. These processes must be energy-efficient and minimize waste production.

Another challenge is the recycling of plastics and composites, which make up an increasing share of vehicle weight. Here, additives for polymer degradation, such as photodegradable catalysts or enzymes, are used to accelerate material breakdown under controlled conditions. Manufacturers of chemical raw materials are also developing materials with a higher proportion of recycled components that meet the strict requirements of the automotive industry for mechanical properties and long-term stability. The circular economy is thus becoming not only an ecological but also an economic necessity.

Need assistance selecting raw materials for electromobility?

GCG Group supplies a broad portfolio of chemical raw materials for the automotive industry, including battery additives, lightweight materials, and safety systems. For each raw material, we provide detailed technical data sheets and safety data sheets (SDS) and are happy to help you select the optimal solution for your production. Contact us – or browse our catalog of over 1,300 products right away.