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

The article examines the challenges faced by China’s electric vehicle (EV) industry in ensuring battery safety, focusing on recent incidents involving Xiaomi Auto’s flagship Su7 sedan and Li Auto’s Mega van. Xiaomi had initially gained acclaim for its innovative battery layout, using vertically downward-facing cells developed with CATL to direct flames and toxic gases away from occupants in crashes. This design was touted as a breakthrough in mitigating fire risks, a persistent issue in EVs. However, fatal accidents in 2025, where Su7 batteries ignited upon impact causing multiple deaths, along with a spontaneous fire in a Li Auto vehicle, exposed the limitations of layout-based safety measures and reignited public concerns about EV battery risks. Despite improvements in battery cell quality, manufacturing, and management systems that have reduced fire incidents overall, the article highlights that the fundamental vulnerabilities remain tied to cell chemistry, engineering structure, thermal management, and especially battery layout decisions. Chinese automakers predominantly use prismatic lithium-ion cells arranged vertically, either upright or