China's EV battery fires test the limits of layout-led safety

The article discusses the challenges China’s electric vehicle (EV) industry faces regarding battery safety, focusing on recent incidents involving Xiaomi Auto’s flagship Su7 sedan and other EV models. Xiaomi had initially gained acclaim for its innovative battery layout, using vertically mounted, downward-facing cells developed with CATL, designed to direct flames and toxic gases away from occupants in crashes. This "cell inversion technology" was touted as a breakthrough in mitigating fire risks, a persistent concern in the EV sector. However, two fatal accidents involving the Su7 in 2025, where batteries ignited upon impact and trapped occupants inside, severely undermined these safety claims. Additionally, a spontaneous fire in a Li Auto Mega van further heightened public fears, illustrating that battery fires can occur even without collisions. Despite overall improvements in battery safety due to better cell quality, battery management systems, and manufacturing standards, the article emphasizes that risks remain tied to cell design, thermal management, and battery layout within integrated vehicle structures. Lithium-ion cells, including