No fire, no explosion
What China's GB 38031-2025 Means for EV Batteries
With GB 38031-2025, China significantly tightens the safety regulations for EV batteries. Even fire and explosions should be excluded for a long time, even in the event of severe defects. This standard aims to set new benchmarks worldwide.
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With GB 38031-2025, China aims to usher in a new era of battery safety: "no fire, no explosion" is the motto. What initially sounds like a technical detail could fundamentally change the global EV market.
When talking about electromobility, most people think of range, charging times, or CO₂ balance. However, another important aspect is the safety of drive batteries (traction batteries). Some media and people have repeatedly stirred up sentiment against electric cars with half-knowledge by painting horror scenarios that have little to do with reality.
With the new standard GB 38031-2025 (“Safety Requirements for Power Batteries for Electric Vehicles”), China is now raising the bar to a new level. But what is behind the “No Fire, No Explosion” formula, how does the new standard differ from previous ones, and what does this mean for manufacturers worldwide? A look into the details of test methods, transition periods, international comparisons, and impacts on the entire value chain.
Background: Why a new battery standard?
Lithium-ion batteries are the heart of modern electric vehicles, but they carry risks: overheating, mechanical damage, or electrical faults can lead to thermal runaway - with dramatic consequences: fire, explosion, toxic smoke gases. The previous standards (such as GB 38031-2020 or IEC 62660 in Europe) relied on warning systems and time delays, but spectacular incidents and rapid market growth made improvements necessary
China, now the largest and most dynamic market for electric vehicles, aims to establish itself as a pioneer in battery safety with the new standard. The goal: zero tolerance for fire and explosion, even under extreme conditions.
What is new in GB 38031-2025? - The key innovations in detail
“No Fire, No Explosion” (At least 2 hours): Batteries must not catch fire or explode even after a severe internal defect (e.g., cell short circuit) for at least 120 minutes. This increases the time frame by 24 times compared to the old standard (5 minutes). Goal: Even in difficult rescue or accident situations, there is enough time for passengers and rescue workers.
Early warning system and smoke protection: An alarm must be triggered within 5 minutes, with no visible smoke reaching the passenger compartment. For the first time, the focus is consistently on protecting vehicle occupants.
New test methods and extended examinations: GB 38031-2025 prescribes a whole arsenal of new tests:
Thermal Propagation Test: Simulation of a thermal runaway in the pack, where the entire pack must withstand.
Bottom Impact Test: Simulation of an impact from below to realistically test the vulnerability of bottom-mounted packs (Cell-to-Body).
Post-Fast-Charging Test: After 300 fast charging cycles, a short circuit test follows. The battery must remain safe.
Extended abuse and environmental tests: Mechanical, electrical, and chemical stressors are more extensively covered.
- Certification and proof of compliance: Batteries must be tested by accredited bodies such as the China Automotive Technology and Research Center (CATARC). In the event of changes to the pack (e.g., component/material changes), targeted retests are required.
Excursus: International comparison between China, USA, and EU - Similarities and differences in battery regulations
USA - FMVSS 305a (Draft): In the United States, FMVSS 305a (“Federal Motor Vehicle Safety Standard No. 305a”) is currently in preparation, which aims to expand the existing regulations for electric vehicles. The draft introduces specific performance and risk mitigation requirements for high-voltage battery systems in passenger cars and commercial vehicles for the first time. Key contents include protection against electric shock, fire limitation, and risk minimization measures in accidents. Unlike China's GB 38031-2025, FMVSS 305a does not yet require complete fire or explosion prevention after a thermal runaway event. The focus is more on crash safety and electrical isolation, supplemented by requirements for the battery management system.
European Union - EU Battery Regulation: With the EU Battery Regulation (EU-BattVO), the EU pursues a comprehensive approach that links safety issues with sustainability, circular economy, and transparency along the entire value chain. The regulation sets requirements for the carbon footprint, recyclability, and traceability of batteries, among other things. For technical safety, international standards such as IEC 62660 are applied, which focus on mechanical, electrical, and thermal tests. Unlike China's GB 38031-2025, the EU does not prescribe an explicit zero tolerance for fire or explosions but relies on an integrative safety and environmental concept.
FAQ: The most important questions and answers about GB 38031-2025
1. When does the new standard come into effect?
For new vehicle models from 1 July 2026, for existing models there is a transition period until 1 July 2027
2. Which batteries are affected?
Traction batteries for electric vehicles (passenger cars, commercial vehicles), but not auxiliary or starter batteries.
3. What is the most important innovation compared to 2020?
Fire and explosion are excluded for at least 2 hours after thermal runaway; smoke protection is mandatory.
4. How is certification carried out?
Only by recognised third parties (e.g. CATARC), proof is also required for pack changes.
5. How do the requirements differ from the EU/USA?
China: uncompromisingly safety-driven; EU: focus on sustainability/circular economy, safety standards less stringent; USA: standards in transition, but so far less strict.
6. What does this mean for suppliers?
Higher development effort, more test cycles, stronger documentation requirements - and potentially increasing market entry barriers for smaller providers.
7. Which cell chemistries are advantageous?
LFP and solid-state batteries are considered less prone to fire, could benefit from the standard.
8. Are there threats of shortages or price increases?
Yes, especially for rare raw materials and due to cost pressure on small providers.
9. Will the standard be adopted worldwide?
Not yet, but the global signal effect is strong - experts expect imitation tendencies, especially emerging markets and OEMs with China ambitions will follow suit.
10. Are there any exceptions or transitional arrangements?
Currently, the deadlines apply as described above; detailed regulations are still being specified by the authorities.
These are the challenges and impacts of GB 38031-2025 for manufacturers
The new requirements are technically and economically demanding. They affect the entire value chain from material selection, cell chemistry, manufacturing through testing to vehicle integration.
The technical challenges include:
Micron precision & purity: Even the smallest impurities or manufacturing errors can lead to catastrophic failures. Highest QA standards, inline monitoring, and automation become mandatory.
Thermal management: Multilayer thermal management (cell, module, pack) is indispensable.
Chemistry and material innovation: With the new standard, LFP cells (less prone to fire) and solid-state batteries could gain further importance.
Testing effort: The number and complexity of tests increase significantly (7 cell, 17 system tests, new triggers, simulation methods).
Additionally, there are some economic impacts and market developments:
Cost increase: Industry experts expect additional costs of 10 to 20% per battery pack. For small manufacturers, this could be existentially threatening. This could lead to a wave of consolidation.
Market access: Only certified packs may be sold/imported in China from 2026. The obligation to provide proof in case of changes complicates flexibility and increases the hurdles for new players.
Strengthening of market leaders: Corporations like CATL, BYD, or Gotion High-Tech benefit from economies of scale and R&D budgets, as they already partially meet the standard. In detail, CATL has already passed the new tests (including thermal propagation and bottom impact) with its Qilin battery - and this with both NMC and LFP chemistry. Zeekr, Lotus, Neta, Avatr, Li Auto, and Aito are already using the Qilin technology today. BYD, also involved in the standard, is likely to soon comply with its Blade batteries as well, but as of June 2025, official certification is only available for CATL.
This article was first published
at all-electronics.de
