A new type of electric bicycle battery is gaining traction in the industry, potentially ushering in unprecedented levels of safety and security for riders. Get ready, because we’re quickly approaching the age of the potted e-bike battery.
There’s no doubt that fire safety is an important subject when it comes to e-bike batteries. Despite the actual number of battery fires being incredibly low compared to tens of millions of e-bikes on the road, the lethal effects of just a single fire drive home the importance of the issue.
Now, a new type of manufacturing process is growing in popularity, claiming to significantly increase the safety of e-bike batteries by reducing the risk of fires, even when the battery is abused or damaged.
Potting, which uses a hardening resin poured between cells to isolate them from each other and the environment, can mitigate the two biggest factors resulting in fires: corrosion and physical damage.
As we learned from battery expert Luke Workman on the Wheel-E Podcast, salt water spray and vapor penetrating the seals in an e-bike battery case can slowly corrode battery cells, eventually leading to a short circuit. Even when properly sealed, physical damage to a battery, such as from a major drop or a crash, can also rupture cells or potentially lead to short circuits, which can, on rare occasions, result in fires.
We recently learned from Pedego, a major national e-bike brand, that it was adopting new potted e-bike batteries that use heat-absorbing resin between cells. Potting the batteries and enclosing the cells in a thermally conductive material helps Pedego protect the battery from impact and puncture damage, and also helps dissipate heat more effectively.
This heat management is vital, as excessive heat can lead to thermal runaway, a condition where increasing temperature causes further heat release, escalating into potentially hazardous situations.
Another advantage is that potted batteries can significantly extend the lifespan of e-bike batteries by reducing the wear and tear associated with vibration and repeated impact—common issues for bicycles used on a variety of terrains. Components such as electrical connectors and nickel conductor strips can sometimes vibrate loose in e-bike batteries, often requiring access to the battery’s internals to diagnose and fix the problem.
Potting resin can be applied over cells similarly to this artistic representation (though the cells would be welded together first)
The solidified potting material stabilizes the battery cells, minimizes movement within the casing, and offers a buffer against the jolts and bumps of everyday riding. This stabilization not only maintains the integrity of the battery but also ensures consistent performance and reliability, which are crucial for users who rely on e-bikes for regular commuting or recreational activities.
Pedego’s adoption of potted e-bike batteries follows quickly behind Rad Power Bikes’ announcement that it was introducing its own potted battery design. Neither are the first movers in this respect, with companies like Luna Cycle and Grin Technologies beating them by many years.
But the major difference this time is that both companies with recent announcements are major national brands, not smaller e-bike companies with less industry influence.
While the original companies deserve credit as first movers, in many cases, it is the first followers who result in the biggest shifts.
Just like with these new potted batteries, the first followers demonstrate that it is no longer a coincidence, this new trend is a pattern.
And with major national brands adopting the safety benefits of potted batteries, it will come as no surprise when other companies begin following this lead.
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Ford is testing a new electrified Mustang that may not be as electric as it seems. The next-gen Mustang is apparently already in development. Here’s what we know about it so far.
Is Ford launching an electrified Mustang Hybrid?
After postponing around $12 billion in planned spending on electric vehicles in 2023, Ford’s CEO Jim Farley said the company would lean more into hybrids.
Farley told investors and analysts on the company’s Q3 2023 earnings call that he’s “so thankful we have kept our foot on the gas to freshen our ICE and HEV products as we enter a changing market.”
Ford’s CFO, John Lawler, reaffirmed the company’s plans later that year, saying the company would use hybrids as a bridge to fully electric vehicles.
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“With EV adoption slower, hybrids are going to be a bigger part,” Lawler said, adding that Ford “became a little bit complacent” on hybrid tech. Last year, Ford said it would introduce a hybrid version for every gas-powered vehicle in its lineup by 2030.
2025 Ford Mustang Mach-E (Source: Ford)
Ford is apparently making good on its promise with a new Mustang hybrid in development. According to a new report from Ford Authority, the Mustang hybrid, internally code-named S650E, is in development, and prototypes are already being tested.
The report claims the new Mustang has entered the Technology Prove-Out stage, suggesting it will be electrified to some degree.
Ford Mustang Mach-E Rally (Source: Ford)
Whether it will be a traditional hybrid or a plug-in hybrid vehicle (PHEV) remains unclear. Although the company has yet to confirm it, Farley said that a “partially electrified Mustang coupe” was a strong possibility, and Ford’s Performance unit is already testing hybrid powertrains.
Electrek’s Take
Will the new Mustang hybrid sit alongside the Mach-E in Ford’s lineup? Ford’s electric crossover SUV remains one of the top-selling EVs in the US, so it’s unlikely to go anywhere, but it is due for a refresh with so many new rivals entering the market.
Through August, Ford sold 34,319 Mustang Mach-Es (+6.7% YOY) in the US. The gas-powered Mustang continues to fall out of favor, with 31,015 units sold in the first eight months of 2025, 8.3% fewer than during the same period in 2024.
With Hyundai, Stellantis, Honda, and several other global OEMs planning to launch new hybrid models in the US, the Ford Mustang hybrid doesn’t come as a total surprise. We will still have to wait for the official word from Ford, but a new electrified Stang seems more than likely.
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Transocean Barents, an oil platform passes through Canakkale Strait as vessel traffic suspended in both directions in Canakkale, Turkiye on November 12, 2024.
Enishan Keskin | Anadolu | Getty Images
Shares of Transocean plunged Thursday after the offshore driller announced the sale of a large number of shares at a discount.
Transocean is planning to sell 125 million shares at a price of $3.05, significantly lower than Wednesday’s close of $3.64. It is offering 25 million shares more than it originally planned.
The Swiss company’s stock was last down 14.8% premarket. The offering is expected to close on Friday.
Transocean expects to book about $381 million from the sale. It will use the proceeds to pay off debt.
(Correction: Updates with correct share offering price.)
New York City’s new 15 mph speed limit for electric bikes is officially set to take effect next month, in what city officials claim is a move to improve street safety. But not everyone is convinced the crackdown is targeting the real threat on the roads.
The new limit, approved earlier this year, applies to e-bikes, mopeds, and other micromobility vehicles operating in city bike lanes. Riders caught exceeding 15 mph could face warnings or citations, though the exact enforcement strategy remains murky. The NYPD says it will focus on “education first,” but given the city’s track record, that could just be the calm before the ticket storm.
The rule comes amid growing concerns from some residents and officials about rising speeds among e-bike riders, especially delivery workers who often rely on throttle-equipped bikes to meet tight deadlines. But while the new speed cap is aimed at micromobility vehicles, there’s a noticeable omission: cars, trucks, and SUVs, which continue to be allowed to travel at 25 mph – and in practice, often much faster – even though they pose exponentially more risk to vulnerable road users and are responsible for orders of magnitude more deaths each year.
It’s a move that raises eyebrows and has resulted in thousands of publicly-submitted comments that the New York Department of Transportation has seemingly ignored.
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After all, the majority of traffic fatalities in New York City don’t involve e-bikes. They involve cars. And while some e-bike riders certainly ride irresponsibly, the blanket limit nearly cuts in half the more widely accepted e-bike speed limits used around the US, and doesn’t even apply to pedal bikes, which can easily exceed such speeds despite nearly identical average weights when factoring in the vehicle and rider. Not to mention, it ignores the critical role that e-bikes play in reducing traffic congestion and emissions, especially in the delivery and commuting sectors.
So while New York is slowing down its most efficient and sustainable form of urban transport, it’s letting the real heavyweights keep their speed. If the goal is safety, then it’s fair to ask: why aren’t cars being asked to go 15 mph too?
Because once again, it seems the rules are written for the powerful – not the vulnerable.
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