Barrier Solutions for Clean and Efficient EV Battery Production

The adoption of electric vehicles (EVs) has been increasing. With EV battery costs projected to decrease by almost 50% by 2026, the global shift toward sustainable transportation is gaining momentum.¹ However, the core component of these vehicles, EV batteries, poses testing manufacturing challenges.

Image Credit: Protective Industrial Products, Inc.

Microscopic contaminants, often introduced by human activity, can jeopardize the delicate processes necessary for high-quality battery performance. To mitigate this risk, implementing advanced cleanroom solutions and using specialized personal protective equipment (PPE) are essential.

The Contamination Challenge in EV Battery Manufacturing

The manufacturing process greatly impacts the performance of lithium-ion battery (LIB) cells throughout their lifespan.² Battery components including cathodes, anodes, and separators, must be assembled in stringent cleanroom settings to guarantee optimal performance and safety.

Contaminants introduced during production can lead to internal short circuits, cause mechanical damage to the separator, and, if electrically conductive, promote dendrite formation. This latter process degrades battery performance and increases the risk of thermal runaway, a spontaneous exothermic reaction that can spread to adjacent cells, which can lead to severe consequences.^3,4

Such failures can result in substantial financial and operational setbacks in extreme cases. A notable example occurred in 2020 when BMW issued a global recall of 26,700 plug-in hybrid EVs. According to a spokesperson, the increased fire risk was suspected to have been caused by contamination during the battery cell production process, which was traced back to one of two suppliers.⁵

The Role of Controlled Environments

Controlled environments regulated for air pressure, temperature, and cross-contamination are essential for producing high-performance EV batteries. These spaces are designed to prevent even the smallest contaminants, such as particulates, from compromising the complex components of LIBs.

However, contamination control involves more than just particulates, moisture presents a particularly serious threat. Organic electrolytes in LIBs have high sensitivity to moisture, with levels greater than 20 ppm negatively impacting performance, safety, and longevity. This sensitivity highlights the critical need to maintain significantly low water content throughout the battery production process.⁶

Achieving these strict conditions often increases energy consumption, infrastructure complexity, and production costs, making efficient contamination control solutions even more essential.⁶ For these settings, Protective Industrial Products (PIP) provides a selection of wearable garments that serve a dual purpose: safeguarding workers by minimizing exposure to hazardous materials while also protecting the manufacturing process by preventing human-borne particles, fibers, moisture, and static discharge from contaminating vital areas.

Cleanroom Solutions for EV Manufacturing

PIP offers a catalog of ISO-rated products designed to minimize contamination risks in controlled environments.

1. ESD Safe Cleanroom Garments

Humans are the primary source of particulate contamination in cleanrooms. PIP’s electrostatic dissipative (ESD) safe garments, including reusable coveralls, adjustable hoods, and fiber sole boots, tackle this issue by:

• Preventing fiber shedding and particulate release
• Neutralizing static charges that attract and retain contaminants
• Fulfilling ISO 4 to ISO 8 cleanroom standards, ensuring compatibility with various production requirements.

Constructed from advanced materials and designed for ergonomic comfort, these garments provide a reliable barrier against human-borne contaminants while allowing for an excellent range of motion.⁷

2. Respirators and Dust Masks

A major source of airborne particulates in cleanrooms is the human respiratory system. PIP’s selection of respirators and dust masks, including NIOSH-approved N95 and P100 models, offers:

• Advanced filtration to contain bioburden and particulates exhaled by workers
• Improved comfort and a secure fit, enabling extended use in demanding environments

These products protect personnel and sensitive manufacturing processes by controlling respiratory emissions.⁸

3. ESD Safe Cleanroom Hand Protection

Gloves provide essential ESD properties to prevent uncontrolled static discharge and offer durable particulate protection, shielding critical surfaces from contaminants attracted by static buildup. Available in single-use options such as QRP^® Qualatrile^® (ISO 5 – Class 100) and CleanTeam^® (ISO 4 – Class 10) gloves, they are powder-free, silicon-free, and designed for exceptional comfort and tactile sensitivity.⁷

4. Eye and Face Protection

Protecting the face against shedding bioburden is crucial. PIP safety goggles and face shields provide:

• Protection against liquid splashes and particulates, meeting ANSI Z87.1 +2015 standards.
• Clarity and acuity to ensure accuracy in high-stakes manufacturing tasks.⁹

Conclusion: Powering Progress Through Contamination Control

The shift toward electric vehicles is about cleaner transportation and entails ensuring safety, dependability, and innovation throughout each stage of EV production. As demand for EVs grows, maintaining pristine manufacturing environments is essential for developing safe, efficient, and long-lasting batteries. Contamination from particulates or moisture can jeopardize battery performance and durability, making advanced cleanroom solutions necessary.

PIP provides state-of-the-art PPE that safeguards workers and the sensitive manufacturing processes at the core of EV battery production. From gloves and garments to respirators and goggles, these solutions address the many challenges of EV manufacturing, ensuring that human-borne contaminants and static electricity do not hinder progress.

Manufacturers can achieve the highest quality and safety by upholding cleanroom standards and integrating advanced PPE. The future of sustainable transportation relies on advancements in battery technology and the environments in which these batteries are produced. By implementing PIP’s cleanroom solutions, the industry is poised for a cleaner, safer, and more electrified future.

References and Further Reading

1. Goldman Sachs (2024). Electric vehicle battery prices are expected to fall almost 50% by 2026. (online) Goldmansachs.com. Available at: https://www.goldmansachs.com/insights/articles/electric-vehicle-battery-prices-are-expected-to-fall-almost-50-percent-by-2025.
2. Evans, D., et al. (2023). Detection of Manufacturing Defects in Lithium-Ion Batteries-Analysis of the Potential of Computed Tomography Imaging. Energies, 16(19), pp.6958–6958. https://doi.org/10.3390/en16196958.
3. Grabow, J., et al. (2022). Particle Contamination in Commercial Lithium-Ion Cells—Risk Assessment with Focus on Internal Short Circuits and Replication by Currently Discussed Trigger Methods. Batteries, 9(1), pp.9–9. https://doi.org/10.3390/batteries9010009.
4. Xu, X., et al. (2022). Dendrite‐accelerated thermal runaway mechanisms of lithium metal pouch batteries. SusMat, 2(4), pp.435–444. https://doi.org/10.1002/sus2.74. 
5. BMW UK. (2025). BMW UK RF. (online) Available at: https://faq.bmw.co.uk/s/article/Is-there-a-recall-on-BMW-PHEV-cars-3nmue (Accessed 6 Mar. 2025). 
6. Li, P., et al. (2024). A moisture/acid-purified and thermoregulatory separator promises hygroscopic electrolytes in lithium-ion batteries. Chemical Engineering Journal, 500, p.157564. https://doi.org/10.1016/j.cej.2024.157564.
7. Protective Industrial Products (2025). Bringing the Best of the World to You^® | Protective Industrial Products. (online) Protective Industrial Products. Available at: https://us.pipglobal.com/en/products/?scID=2561&ccID=11697&color=--White--&fabric=--Disctek+2.5--&sizes=--M-- (Accessed 6 Mar. 2025).
8. Protective Industrial Products (2025). Bringing the Best of the World to You^® | Protective Industrial Products. (online) Protective Industrial Products. Available at: https://ca.pipglobal.com/en/products/respiratory-protection-guide/ (Accessed 6 Mar. 2025).
9. Protective Industrial Products (2025). Safety Products Controlled Environment Quick Reference Guide. Available at: https://us.pipglobal.com/archive/literature/PIP-Controlled-Environment-Ref-Guide-2023.pdf (Accessed 6 Mar. 2025).

This information has been sourced, reviewed and adapted from materials provided by Protective Industrial Products, Inc.

For more information on this source, please visit Protective Industrial Products, Inc.