Nanosensor Array-on-a-Chip: An Early Warning System for EV Thermal Runaway

The Challenge

As Australia accelerates the adoption of electric vehicles (EVs) and battery energy storage systems to support Net Zero goals, the risk of lithium-ion battery fires is emerging as a significant safety challenge. Unlike conventional fires, battery thermal runaway events begin internally, releasing toxic and highly flammable gases well before smoke, visible flames, or significant temperature changes occur. Existing fire detection systems rely primarily on smoke and heat sensors, which often provide warning only once thermal runaway is underway, leaving little opportunity for intervention and increasing the risk of asset loss, environmental damage, and threats to human safety. The challenge is therefore to develop a reliable early-warning capability that can identify the chemical signatures of battery failure at its earliest stages. Addressing this gap is critical to ensuring public confidence in EV technologies and the safe transition to an electrified, low-carbon future.

The Solution

The proposed solution is an Integrated Multi-Gas Sensor Chip (IMG-SC) that can detect the earliest chemical warning signs of lithium-ion battery failure, well before conventional fire detection systems respond. Rather than relying on smoke or heat sensors, the technology monitors gases released during the initial stages of battery degradation, including electrolyte vapours and other characteristic off-gassing compounds. The project combines UNSW’s expertise in nanosensor development with the University of Sydney’s advanced electrochemical nanoprinting capabilities to create a compact “array-on-a-chip” containing multiple specialised sensing materials on a single substrate. The resulting sensor will be integrated into a standalone, battery-powered device connected to Flame Security International’s IoT fire protection network. By providing substantially earlier warning of thermal runaway events, the technology aims to enable proactive intervention, improve EV safety, and support the safe expansion of electrified transport and energy systems.

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