Ensuring Battery Safety in Electric Vehicles: Challenges, Developments, and Future Perspectives

Abstract With the rapid adoption of electric vehicles (EVs), battery safety has emerged as a cornerstone of innovation in the automotive industry. This review systematically examines critical safety challenges, such as thermal runaway, interfacial degradation, and mechanical abuse, which threaten performance, reliability, and consumer confidence. By bridging material science with systems engineering, it is analyzed failure mechanisms across scales, from atomic‐scale dendrite formation to module‐level thermal propagation. It is also evaluate advanced diagnostic tools (e.g., machine learning‐driven fault detection). Furthermore, emerging solutions is highlighted, such as self‐healing electrolytes, nanostructured thermal barriers, and smart battery management systems that enhance resilience while maintaining energy density. This work critically assesses the trade‐offs between scalability and safety in next‐generation technologies. This review provides a roadmap for researchers and engineers to design highly durable and fail‐safe batteries for sustainable transportation by integrating fundamental insights with practical applications.