We need to talk about Rad Power Bikes’ new e-bike batteries
Electric bikes just may be the biggest transportation revolution of our generation, helping millions replace car usage with more affordable, more efficient alternatives. But there’s no denying that concerns have been swirling about the safety of e-bike batteries, even if such fire fears have primarily been overblown by much of the media.
Leading electric bicycle maker Rad Power Bikes has just unveiled its new “Safe Shield Battery” in an effort to mitigate worries over e-bike battery safety. And it’s something we need to talk about.
The whole underlying issue here is based on the fact that e-bike batteries are usually comprised of dozens of smaller, energy-dense lithium-ion battery cells. Those cells are similar – and sometimes identical – to the battery cells used in everything from electric cars to power tool battery packs.
The individual battery cells store lots of energy and are generally quite safe. However, danger can occur when the cells are punctured or short-circuited, with the latter often happening when water makes its way into battery packs over time. Well-made e-bike batteries use several methods to mitigate these risks, and the result is that battery fires are exceedingly rare. Even in e-bikes, which seem to unfairly receive the brunt of lithium-ion battery fire scaremongering, such fires occur in a tiny, tiny fraction of a percent of e-bikes.
To put things into perspective, New York City often gets labeled as the epicenter of e-bike fires, yet New Yorkers are somewhere around 5x more likely to die on the subway than from an e-bike fire.
However rare though, e-bike fires can and do occur in poorly made batteries or in battery packs that have been abused, damaged, or otherwise misused. And that’s exactly what it looks like Rad Power Bikes set out to solve with its new Safe Shield e-bike batteries.
The secret sauce in Rad’s batteries isn’t actually the battery cells themselves. Those are fairly standard cells like you’ll find in many other e-bike batteries. The major difference is how the battery packs are constructed.
They use a method known as potting, which basically encapsulates electronics in a waterproof resin barrier. It’s common in electronics that will live much of their lives outdoors, as it seals the sensitive components from moisture.
Remember that mosquito from Jurassic Park that was encased in tree resin amber? That’s kind of the idea with potted batteries, just with a urethane resin instead of tree sap. The battery pack already uses quality construction methods, but then to top it off, the entire thing is filled with resin that makes it impermeable to water – or intruding fingers, tools, or anything else. It’s forever sealed away from the world (though Rad says it’s still recyclable in their battery recycling program).
But it’s not just any resin, the idea is that it is also thermally insulating, which means that if one battery cell ever did go rouge and start overheating (an incredibly, incredibly rare event in well-made battery cells), the barrier would help protect any nearby cells from joining in and developing what is known as a “thermal runaway” condition that is what ultimately leads to the spread of most battery fires.
We spoke to one of the country’s leading battery experts Luke Workman on our Wheel-E podcast last year, who has often performed forensic evaluations in the aftermath of battery fires. When we asked him if there was anything that could be done to help mitigate the fire risks we were seeing in the e-bike industry, such as the widespread adoption of UL certification, he had a simple answer: “Potting.”
Workman explained that he’s performed post-fire forensic analysis on plenty of UL-certified battery packs, indicating that such certification isn’t a guarantee of safety. “You can pass UL water ingress tests with a bit of strategically placed tape over the battery seams,” he explained at the time. But potting was the truly safest method of building batteries that wasn’t intended to merely pass a certification test, but rather to actually ensure the battery cells were isolated and protected.
At the time, there was just one major company producing potted e-bike batteries, Luna Cycle, but it hasn’t gained significant traction anywhere else in the e-bike industry.
At least not until now.
With Rad Power Bikes adopting potted battery design practices, the entire industry has been put on notice. Until new technologies like fireproof solid-state batteries become commonplace, potted batteries are the single best defense against battery fires. And with one of the largest e-bike retailers in the country hopping aboard the potted train, others are all but sure to follow.
Rad has a history of setting examples that are quickly copied throughout the US e-bike industry. New e-bike models like the RadRunner spurred several copycats and jumpstarted the utility e-bike market. Rad’s expansions into several large brick-and-mortar stores pre-empted a major push by several other US e-bike companies to expand dealer networks with independent bike shops. Rad’s electric trike was quickly followed by several other competitors seeking to undercut its price.
In none of these examples was Rad the first e-bike company to make a major move, but it was the first big e-bike company to do so, and thus helped shift the industry each time. And while there’s no guarantee how the industry will react, especially in a year where e-bike sales have lagged behind the post-pandemic boom, there’s no doubt that a major e-bike maker finally adopting potted battery technology is a sign of where the industry is headed. How long it takes us to get there though, that’s anyone’s guess.
resin pouring image via: Pexels
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Kia’s electric SUVs are taking over. The EV3 is the best-selling retail EV in the UK this year, giving Kia its strongest sales start since it arrived 34 years ago. And it’s not just in the UK. Kia just had its best first quarter globally since it started selling cars in 1962.
Kia EV3 is the best-selling EV in the UK through March
In March, Kia sold a record nearly 20,000 vehicles in the UK, making it the fourth best-selling brand. It was also the second top-seller of electrified vehicles (EVs, PHEVs, and HEVs), accounting for over 55% of sales.
The EV3 remained the best-selling retail EV in the UK last month. Including the EV6, three-row EV9, and Niro EV, electric vehicles represented 21% of Kia’s UK sales in March.
Kia said the EV3 “started with a bang” in January, darting out as the UK’s most popular EV in retail sales. Through March, Kia’s electric SUV has held on to the crown. With the EV3 rolling out, Kia sold over 7,000 electric cars through March, nearly 50% more than in Q1 2024.
The EV3 was the best-selling retail EV in the UK in the first quarter and the fourth best-selling EV overall, including commercial vehicles.
Starting at £33,005 ($42,500), Kia said it’s the “brand’s most affordable EV yet.” It’s available with two battery packs, 58.3 kWh or 81.48 kWh, good for 430 km (270 miles) and 599 km (375 miles) of WLTP range, respectively.
With new EVs on the way, this could be just the start. Kia is launching several new EVs in the UK this year, including the EV4 sedan (and hatchback) and EV5 SUV. It also confirmed that the first PV5 electric vans will be delivered to customers by the end of the year.
Electrek’s Take
Globally, Kia sold a record 772,351 vehicles in the first quarter, its best since it started selling cars in 1962. With the new EV4, the brand’s first electric sedan and hatchback, launching this year, Kia looks to build on its momentum in 2025.
Kia has also made it very clear that it wants to be a global leader in the electric van market with its new Platform Beyond Vehicle (PBV) business, starting with the PV5 later this year.
Earlier today, we learned Kia’s midsize electric SUV, the EV5, is the fourth best-selling EV in Australia through March, outselling every BYD vehicle (at least for now). The EV5 is rolling out to new markets this year, including Canada, the UK, South Korea, and Mexico. However, it will not arrive in the US.
For those in the US, there are still a few Kia EVs to look forward to. Kia is launching the EV4 globally, including in the US, later this year. Although no date has been set, Kia confirmed the EV3 is also coming. It’s expected to arrive in mid-2026.
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Environment
Podcast: Tesla’s disastrous deliveries, more Trump tariffs, EV delivery numbers, and more
In the Electrek Podcast, we discuss the most popular news in the world of sustainable transport and energy. In this week’s episode, we discuss Tesla’s disastrous deliveries, more Trump tariffs, EV delivery numbers, and more.
The show is live every Friday at 4 p.m. ET on Electrek’s YouTube channel.
As a reminder, we’ll have an accompanying post, like this one, on the site with an embedded link to the live stream. Head to the YouTube channel to get your questions and comments in.
After the show ends at around 5 p.m. ET, the video will be archived on YouTube and the audio on all your favorite podcast apps:
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Charging your EV in freezing weather could soon become dramatically faster, thanks to a big breakthrough from the University of Michigan engineers.
Neil Dasgupta, U-M associate professor of mechanical engineering and materials science and engineering and corresponding author of a study published in Joule, and his team have developed an innovative battery structure and coating that can boost lithium-ion EV battery charging speeds by a whopping 500%, even at frigid temperatures as low as 14F (-10C). “Charging an EV battery takes 30 to 40 minutes even for aggressive fast charging, and that time increases to over an hour in the winter,” Dasgupta explained. “This is the pain point we want to address.”
Freezing weather has traditionally been harsh on EV batteries because it slows down the movement of lithium ions, resulting in slower charging speeds and reduced battery life. Automakers have tried thickening battery electrodes to extend driving range, but this makes some of the lithium hard to access, making charging even slower.
Previously, Dasgupta’s group sped up battery charging using lasers to carve pathways around 40 microns in size into the graphite anode. This allowed lithium ions to reach deeper into the battery more quickly. However, cold-weather performance still lagged because a chemical layer formed on the electrodes, blocking the ions. Dasgupta compares this barrier to “trying to cut cold butter,” making charging inefficient.
To solve this, the team coated the battery with a thin, glassy material made of lithium borate-carbonate—only 20 nanometers thick—which prevented the problematic chemical layer from forming. Combined with the microscopic channels, the results were groundbreaking: the modified batteries retained 97% of their capacity even after 100 fast-charging cycles in freezing temperatures.
“We envision this approach as something that EV battery manufacturers could adopt without major changes to existing factories,” Dasgupta noted. “For the first time, we’ve shown a pathway to simultaneously achieve extreme fast charging at low temperatures, without sacrificing the energy density of the lithium-ion battery.”
This innovation could tackle one of the biggest concerns holding potential EV buyers back.
The new battery tech is moving closer to commercialization, supported by the Michigan Economic Development Corporation’s Michigan Translational Research and Commercialization (MTRAC) Advanced Transportation Innovation Hub. The research devices were built at U-M’s Battery Lab and studied with help from the Michigan Center for Materials Characterization.
U-M Innovation Partnerships assisted the team in applying for patents, and Arbor Battery Innovations has licensed the technology for market deployment. Dasgupta and the University of Michigan hold financial stakes in Arbor Battery Innovations.
Read more: California now has nearly 50% more EV chargers than gas nozzles
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