As electric vehicles are being adopted globally, thermal management has become one of the most important areas of focus for EV design and performance. In 2025, thermal management systems are the subject of dramatic evolution across multiple sectors due to advancements in cooling technologies, material science and advanced manufacturing. These thermal management advancements will add benefits to vehicle performance, safety, durability and efficiency – issues that are important for both OEMs and EV users.
Market Overview
The global thermal management market for EVs is undergoing robust expansion. According to Future Market Insights, the global EV thermal management system market is expected to reach USD 3.3 billion in 2025 and surge to USD 16.6 billion by 2035, growing at a CAGR of 21.4%. In India, the EV battery thermal management systems market is projected to touch USD 470.4 million by 2030, rising at a staggering CAGR of 33.1% from 2025 onwards.
This growth underscores the rising demand for efficient cooling technologies to tackle the heat generated by high-capacity batteries, power electronics, and electric motors. The market’s momentum is largely driven by regulatory push, increasing EV adoption, and heightened consumer expectations regarding safety and vehicle range.
Key Components of EV Thermal Management Systems
EVs are composed of several subsystems that require specialized thermal management strategies. Cooling technologies offer effective temperature control in the following critical applications:
1. Battery Thermal Management Systems (BTMS)
Batteries packs are at the heart of all EVs, and the appropriate thermal management is necessary for battery health, energy efficiency, and safety. Advanced cooling technologies such as liquid cooling, air cooling, and the integration of phase change materials (PCMs) are used to stabilize temperature ranges during operation and charging.
2. Power Electronics Cooling
Components such as inverters, converters, and onboard chargers produce considerable heat. Modern thermal management systems utilize liquid cooling, heat sinks, and dedicated thermal interface materials to mitigate thermal runaway and improve energy efficiency.
3. Motor Cooling systems
Electric motors are required to manage thermal energy as well, especially in high-performance applications. While oil spray cooling and water-glycol cooling jackets are not yet widely used in the next-gen EV space, they are helping improve heat transfer.
4. Cabin Climate Control
Thermal management is important for passenger comfort as well. Advanced HVAC is taking advantage of heat pumps and waste heat recovery systems (for cooling) that will provide energy efficiency without impacting thermal comfort.
Revolutionary Cooling Technology
The exploration of revolutionary cooling technologies is revolutionizing the thermal management of electric vehicles in 2025. These technologies are critical in controlling increasing power density and fitting within a compact form factor with modern electric vehicles.
1. Immersion Cooling
Immersion cooling systems completely immerse battery cells in dielectric fluids to allow for direct and uniform conduction of heat. This process reduces spatial thermal gradients which enhances battery performance and safety.
2. Thermally Conductive Adhesives
Resins such as ThreeBond’s 2045B and 2145B are now being used to bond components whilst also providing a high tolerance to heat transfer. These adhesives are an essential piece of modern thermal management and allow for very elaborate packaging without compromising the reliability of electric vehicle modules.
3. Phase Change Materials (PCMs)
By using phase change materials (PCMs), passive thermal management is achieved, either absorbing or releasing heat as heat pipes undergo phase change. They are used to integrate thermal batteries into modules, and transition battery stacks and power electronics by combining techniques of advanced cooling technologies to buffer unexpected peak temperature spikes.
Innovations in Materials
Material innovation is central to the next generation of thermal management systems. In 2025, a number of new classes of materials are transforming cooling technologies:
1. Advanced Polymers (e.g., Stanyl®)
Polymers, such as Stanyl®, show high heat resistance and stability, enabling their use for battery enclosures and power modules in thermal management applications.
2. Nanomaterials
Thermal management materials can play an important role in cooling technologies and electronic applications as they are being enhanced by nanotechnology to increase thermal conductivity. This is effective in helping to keep embedded thermal interface materials effective in cooling technologies and electronic applications which may have geometry restrictions.
3. Lightweight Alloys
Lightweight metals, such as aluminum and magnesium, that can demonstrate excellent conductivity properties are desirable in cooling technologies as they augment cooling performance while virtue of being lower weight.
Manufacturing Innovations
Modern manufacturing techniques are enhancing the precision, integration, and scalability of thermal management systems. These methods ensure that cooling technologies are both cost-effective and efficient.
1. Additive Manufacturing
3D printing allows for intricate thermal management component geometries that would be impossible to create with traditional methods. It also supports customization and weight reduction in cooling technologies.
2. Modular design
Thermal management architectures that are modular allow OEMs to easily transfer cooling technologies between any number of architectures. This means that development timelines are reduced, and system integration is simplified.
3. Automation and AI
AI driven design and production tools enable the optimization of thermal management layouts, prediction of heat flow patterns, and the level of automation increases the consistency of fabrication of cooling technologies, ensuring higher reliability.
Indian sources and collaboration
India’s EV ecosystem is rising in importance in the thermal management space. Indian companies, notably, are providing advanced cooling technologies, and working jointly on R&D initiatives.
1. MAHLE India
MAHLE India has received a “Special Appreciation Award” from Mahindra & Mahindra for being an outstanding thermal management company for intelligent thermal management solutions. The company is also developing adaptive cooling approaches for batteries and cabins.
2. IIT Indore
IIT Indore has developed unique thermal management technologies for EV batteries, and these approaches are being commercialized with EV startups in Bengaluru focused on two-wheelers and three-wheelers.
3. Tata AutoComp Systems
Tata AutoComp is investing heavily in thermal management systems by partnering with international firms to localize state-of-the-art cooling technologies that support many Indian OEM.
Concerns and Future Directions
While prospects are bright, challenges remain. The demand for compact, low-cost/high-performance thermal management systems continues to grow, especially in small EVs and fast charging infrastructure. Future considerations for cooling technologies must also include recyclability and global safety compliance.
Hybrid thermal management systems, integrating active and passive cooling technologies, dominate the future. Emerging technologies in fields involving AI, smart sensors and adaptive controls, will provide further opportunities for improving performance.
Conclusion
In the year 2025, thermal management has transitioned from being an accessory to being front and center in the electric vehicle design stage. Cooling solutions ranging from immersion cooling, nanomaterial-based thermal interfaces, and AI based design solutions, are changing the way the EV operates and innovates into the future.
India’s increasing footing in global thermal management innovation, driven by commercial R&D, partnerships with R&D agencies, and engaged OEMs, reflects India’s importance in this segment of the electrified mobility value chain.
While we get closer to an electric mobility dominance in the future; understanding thermal management and leveraging advanced cooling technologies will be a key enabler in maximising the electric vehicle’s performance.