Innovative battery housing made of aluminum foam by Fraunhofer IWU and Amsted Automotive

Aluminum Battery Housing Made of Aluminum Foam

2025-11-26 Source: Fraunhofer IWU | Translated by AI 2 min Reading Time

Researchers at Fraunhofer IWU, together with employees of the automotive supplier Amsted Automotive, have developed an integrally designed battery housing with aluminum foam sandwiches. The special material structure consists of two solid aluminum sheets enclosing an inner core made of aluminum foam.

The special material structure of the housing consists of two solid aluminum sheets enclosing an inner core made of aluminum foam.(Image: Fraunhofer IWU) — The special material structure of the housing consists of two solid aluminum sheets enclosing an inner core made of aluminum foam.
(Image: Fraunhofer IWU)

The housings of high-voltage batteries in battery-electric cars must meet a wide range of requirements. Safety-relevant aspects include high impact resistance and the ability to absorb energy during crashes or provide protection against short circuits. The material must also be heat-resistant and flame-retardant. Efficient heat dissipation is essential as well. At the same time, the sensitive cells must be protected from excessive cooling at sub-zero temperatures. Stones or road salt must not damage the housing. Additionally, it should fit precisely into the vehicle's underbody structure, contribute to the stiffness of the body, and increase the vehicle's range with a low weight. Aluminum foam meets the requirements to fulfill all these demands equally.

Integrate PCM into Closed-Cell Aluminum Foam

The Fraunhofer IWU and Amsted Automotive have developed an integrally designed battery housing with aluminum foam sandwiches. The specialized material structure consists of two solid aluminum sheets enclosing an inner core of aluminum foam. Cooling structures or a heat storage medium (PCM, Phase Change Material) can be incorporated into these sandwiches if needed.

The Fraunhofer IWU successfully integrated PCM into closed-cell aluminum foam. PCMs can absorb or release very large amounts of thermal energy while changing their state (solid or liquid) without significantly altering their own temperature. This makes them particularly well-suited for efficient thermal management in lithium-ion batteries. Depending on the prioritized properties, pure AAS (specifically: aluminum-aluminum foam sandwiches), AAS with infiltrated PCM, AAS with cooling structures, or AAS with cooling structures and PCM can be implemented.

For battery housings made of aluminum foam to become more widespread in mass-produced vehicles in the future, the researchers led by Dr. Thomas Hipke and Dr. Rico Schmerler are now focusing more on cost-effectiveness. An important factor for future production costs is the raw material. Hipke: "We are increasingly relying on recycled material for the production of aluminum foam. This is not only significantly more cost-effective but also substantially reduces the carbon footprint."

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Date: 08.12.2025

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