PDF Cover

EV Battery Cooling Plates Market

The market for EV Battery Cooling Plates was estimated at $2.4 billion in 2025; it is anticipated to increase to $6.5 billion by 2030, with projections indicating growth to around $18.1 billion by 2035.

Report ID:DS2405022
Author:Chandra Mohan - Sr. Industry Consultant
Published Date:
Datatree
Energy & Power
Battery
EV Battery Cooling Plates
Share
Report Summary
Market Data
Methodology
Table of Contents

Global EV Battery Cooling Plates Market Outlook

Revenue, 2025

$2.4B

Forecast, 2035

$18.1B

CAGR, 2026 - 2035

22.6%

The EV Battery Cooling Plates industry revenue is expected to be around $2.4 billion in 2026 and expected to showcase growth with 22.6% CAGR between 2026 and 2035. Building on this outlook, the EV Battery Cooling Plates market has emerged as a critical pillar of EV battery thermal management, underpinning the safety, performance, and longevity of modern traction batteries across global electric mobility fleets. Rapid electrification of transport, stringent emissions regulations, and OEM strategies to extend driving range and enable ultra-fast charging are collectively accelerating the integration of advanced EV Battery Cooling Plates into the broader electric vehicle battery cooling ecosystem. With passenger car and commercial vehicle applications jointly accounting for about 86.9% of demand, the technology has become deeply embedded in core vehicle platforms rather than remaining a peripheral component choice. This concentration in high-volume automotive platforms, together with ongoing investments in high-energy-density chemistries and higher-voltage battery systems, ensures that EV Battery Cooling Plates remain essential for managing thermal runaway risks, optimizing efficiency, and reducing total cost of ownership over the vehicle lifecycle.

EV Battery Cooling Plates are engineered heat-exchange components integrated directly into battery pack cooling systems, designed to maintain uniform cell temperatures through high-conductivity materials, optimized coolant channels, and compact geometries that fit within constrained pack architectures. Their key features include precise thermal control for lithium-ion modules, compatibility with high-voltage packs, lightweight construction to preserve vehicle range, and scalability from compact passenger cars to heavy commercial vehicles and buses. Major applications span traction battery packs in passenger cars, light and heavy commercial vehicles, and increasingly in fleet and logistics platforms, where robust thermal management supports intensive duty cycles, frequent fast charging, and reliable operation in diverse climatic conditions. Recent trends driving demand include the dominance of the Liquid Technology segment, which generated around $1.61 billion in revenue in 2025 and leverages advanced liquid cooling technology, the development of ultra-thin plates for cell-to-pack and cell-to-chassis architectures, and the integration of sensors and smart controls that enhance the efficiency and responsiveness of EV Battery Cooling Plates across evolving EV platforms.

EV Battery Cooling Plates market outlook with forecast trends, drivers, opportunities, supply chain, and competition 2025-2035
EV Battery Cooling Plates Market Outlook

Market Key Insights

  • The EV Battery Cooling Plates market is projected to grow from $2.4 billion in 2025 to $18.1 billion in 2035. This represents a CAGR of 22.6%, reflecting rising demand across Passenger Car, Commercial Vehicle, and Two-Wheelers.

  • Sogefi Group, Senior Flexonics, and Columbia Staver are among the leading players in this market, shaping its competitive landscape.

  • U.S. and China are the top markets within the EV Battery Cooling Plates market and are expected to observe the growth CAGR of 21.7% to 31.6% between 2025 and 2030.

  • Emerging markets including Indonesia, South Africa and Chile are expected to observe highest growth with CAGR ranging between 17.0% to 23.5%.

  • Transition like Adoption of Advanced Materials is expected to add $1 billion to the EV Battery Cooling Plates market growth by 2030.

  • The EV Battery Cooling Plates market is set to add $15.7 billion between 2025 and 2035, with manufacturer targeting Commercial Vehicle & Two-Wheelers Application projected to gain a larger market share.

  • With

    increasing demand for electric vehicles, and

    Technological Advancements in Battery Cooling Systems, EV Battery Cooling Plates market to expand 667% between 2025 and 2035.

ev battery cooling plates market size with pie charts of major and emerging country share, CAGR, trends for 2025 and 2032
EV Battery Cooling Plates - Country Share Analysis

Opportunities in the EV Battery Cooling Plates

Rapid electrification of commercial electric fleets across Europe is also driving demand for robust electric vehicle battery cooling tailored to intensive duty cycles. Fleet operators seek EV Battery Cooling Plates that balance cost, durability, and straightforward maintenance within integrated battery thermal management systems. Globally, liquid and air technologies will rise from $2.18 billion in 2025 to $5.74 billion by 2030, but growth will be strongest for corrosion-resistant liquid plates used in European last-mile logistics and regional delivery fleets.

Growth Opportunities in Asia-Pacific and Europe

In Asia-Pacific, EV Battery Cooling Plates demand is dominated by passenger car electrification, closely followed by booming electric two-wheelers, creating top opportunities for localized production of advanced battery pack cooling solutions, high-surface-area liquid cooling plates, and cost-optimized EV thermal management systems tailored to compact platforms and high-volume segments; competition is intensifying as regional battery makers, integrated EV manufacturers, and specialized cooling component suppliers race to secure long-term platform contracts, driving differentiation through superior heat flux performance, manufacturability, and integration with battery management systems, while core drivers include strong policy support for zero-emission mobility, rapid charging infrastructure expansion, and urban congestion policies that accelerate adoption of electric passenger vehicles and micro-mobility fleets.
In Europe, EV Battery Cooling Plates are most critical for long-range passenger cars and emerging commercial EV fleets, opening high-value opportunities in premium thermal management for large-format battery packs, modular plate architectures for multi-segment platforms, and lightweight, recyclable plate designs aligned with circular-economy requirements; the competitive environment is shaped by established Tier-1 thermal specialists, precision metal fabricators, and disruptive start-ups in EV battery cooling systems, all competing on lifecycle efficiency, reliability, and system-level integration, while key drivers include stringent CO2 and fleet emission standards, corporate commitments to decarbonize logistics, and growing demand for high-performance EVs, which collectively favour investment in differentiated EV thermal management solutions that enhance range, charging speed, and total cost of ownership.

Market Dynamics and Supply Chain

01

Driver: Rapid EV Adoption and Increasing Demand for Higher Battery Energy Density Solutions

The accelerating global adoption of electric vehicles is also a primary driver for EV battery cooling plates. Passenger cars, commercial vehicles, and two-wheelers are also all transitioning from internal combustion to electric powertrains, creating strong demand for effective thermal management systems. As more vehicles hit roads, manufacturers are also forced to optimize battery cooling to maintain safety and performance. At the same time, battery energy density continues to increase as OEMs pursue longer driving ranges. Higher energy density packs generate more heat during charging and discharging, making advanced cooling plates essential to prevent thermal runaway. Innovations such as micro-channel liquid cooling plates and integrated cooling architectures enable more precise heat removal even in compact battery designs. Together, widespread EV adoption and the push for denser battery cells significantly drive investments in cooling plate technology across global automotive segments.
Stringent safety regulations mandating robust thermal management to prevent overheating and fires are also rapidly shaping the EV battery cooling plate market. Regulatory bodies in North America, Europe, and Asia now emphasize battery system safety, requiring manufacturers to adopt advanced cooling solutions that reduce risks associated with high temperature operation. Cooling plates that regulate battery cell temperatures help extend cycle life and ensure reliability under varied environmental conditions. As automakers target zero defect and long life battery systems, regulatory compliance and customer expectations for dependable performance further elevate demand for sophisticated cooling plate technologies. This trend is also especially evident in premium and commercial EV segments where operational safety and uptime are also critical.
02

Restraint: High Manufacturing Costs and Complex Integration Challenges Limiting Adoption and Profitability

One major restraint for EV battery cooling plates is the high manufacturing cost driven by precision machining, advanced materials, and quality testing requirements. Integrating cooling plates into battery packs adds complexity to thermal management system design, driving up assembly time and cost. For example, automotive OEMs may delay adopting advanced microchannel liquid plates because they raise unit costs compared to simpler passive systems, affecting profit margins on EVs. These cost pressures can slow market demand, especially in lower-priced two-wheeler and entry-level passenger car segments, where buyers are cost sensitive. As a result, scaling production and achieving economies of scale is delayed, constraining revenue growth potential for cooling plate suppliers.
03

Opportunity: Advanced EV Battery Cooling Plates for Solid-State Buses in Asia and High-Performance EV Battery Cooling Plates for Fast-Charging Premium EVs

Emerging solid-state batteries in Asian electric buses require ultra-stable temperature control, opening a new segment for EV Battery Cooling Plates using phase change materials. PCM technologies are forecast to grow globally from $0.18 billion in 2025 to $0.79 billion by 2030, the fastest 34.61% CAGR among cooling types. The most significant upside lies in PCM-enhanced plates for high-capacity intercity and urban transit buses in China, India, and Southeast Asia, where harsh climates challenge conventional battery thermal management.
Surging demand for fast-charging, high-energy-density EVs is intensifying heat loads in electric cars, creating a niche for advanced EV Battery Cooling Plates and battery pack cooling solutions integrated into EV thermal management systems. Automakers are prioritizing liquid cooling plates for EV battery packs, as global liquid technologies are projected to rise from $1.61 billion in 2025 to $4.57 billion by 2030, a 23.2% CAGR. Growth will concentrate in liquid plates optimized for 800V architectures and fast charging cycles.
04

Challenge: Supply Chain Material Constraints and Aluminum Price Fluctuations Impact Production and Demand

Material scarcity and volatility in pricing for key metals such as aluminum and copper used in cooling plates pose significant restraints. Rapid price increases or supply disruptions inflate production costs and squeeze manufacturer margins. For instance, an unexpected rise in aluminum costs can force thermal management suppliers to postpone capacity expansion or renegotiate contracts with EV OEMs, impacting project timelines. These material constraints also slow innovations in new cooling plate designs that rely on specialty alloys. The overall effect is distorted supply chains and reduced market responsiveness, making buyers cautious about committing to long-term cooling plate orders.

Supply Chain Landscape

1

Raw Materials

NovelisConstelliumSGL Carbon
2

EV Battery Cooling Plates

MAHLE GmbHBoyd CorporationColumbia Staver Limited
3

Thermal Management Systems

Denso CorporationHanon SystemsValeo
4

Electric Vehicle OEMs

Passenger Electric VehiclesCommercial Electric VehiclesEnergy Storage Systems
EV Battery Cooling Plates - Supply Chain

Use Cases of EV Battery Cooling Plates in Passenger Car & Two-Wheelers

Passenger Car : Passenger cars represent the largest application for EV battery cooling plates, primarily using liquid cooled aluminum cooling plates due to their high thermal conductivity and lightweight properties. These plates are integrated directly beneath battery modules to maintain optimal operating temperatures during fast charging and high speed driving. Automakers favor aluminum stamped or extruded cooling plates with internal channels that allow coolant circulation for uniform heat dissipation. Their use improves battery lifespan, charging efficiency, and overall vehicle safety. In compact and mid range electric cars, efficient cooling plates also support higher energy density battery packs while keeping system weight low, which directly enhances driving range and consistent performance across varied climate conditions.
Commercial Vehicle : Commercial vehicles such as electric buses, trucks, and delivery vans mainly use robust liquid cooled battery cooling plates made from thicker aluminum or aluminum alloy materials. These vehicles operate under higher load conditions and longer duty cycles, requiring reliable thermal management to prevent overheating during extended operation. Cooling plates are often paired with advanced liquid cooling loops to handle large battery capacities. Fleet operators benefit from improved battery durability, reduced downtime, and stable performance in demanding urban and highway environments. The ability of cooling plates to manage heat during frequent stop start operations and fast charging sessions makes them essential for commercial EV reliability and total cost of ownership control.
Two-Wheelers : Two wheelers primarily adopt compact and cost effective battery cooling plates, often using simplified aluminum or hybrid air assisted cooling plate designs. Electric scooters and motorcycles have smaller battery packs and limited space, making lightweight and thin cooling plates ideal. These plates help dissipate heat generated during acceleration and regenerative braking without adding complexity or excessive cost. Manufacturers use passive or semi active cooling plate systems to balance performance with affordability. Effective thermal management through cooling plates improves battery safety, supports consistent power delivery, and enhances riding comfort, especially in hot climates where two wheelers are widely used for daily commuting.

Recent Developments

The EV battery cooling plates market is advancing with increased deployment of liquid cooling systems and smart thermal management solutions to support higher energy density batteries and fast charging demands. Tier-one suppliers are integrating sensors and control units for real-time temperature regulation, improving battery life and safety. A key trend is the shift toward lightweight aluminum and composite cooling plates that balance thermal conductivity with weight reduction. Growing electric vehicle sales and stringent battery safety requirements are driving innovation in heat dissipation technology and thermal system design.

February 2025 : MAHLE GmbH highlighted its next-generation bionic battery cooling plate and intelligent thermal management solutions, increasing cooling performance ≈10 % and reducing pressure losses by ≈20 %, demonstrating enhanced heat dissipation for EV batteries and fast charging applications. This showcase underscores MAHLE’s focus on innovation in EV battery thermal management systems.
February 2025 : MAHLE GmbH won a first series order to supply high-performance cooling modules for fast charging stations targeting megawatt charging infrastructure for electric commercial vehicles and passenger EVs. Series production is set to begin by the end of 2025, expanding the company’s aftermarket and charging infrastructure product portfolio.
April 2024 : MAHLE GmbH announced it had secured two significant thermal management contracts totaling about €1.5 billion, where integrated thermal management modules will enhance EV cruising range and charging performance across multiple global OEM programs.

Impact of Industry Transitions on the EV Battery Cooling Plates Market

As a core segment of the Battery industry, the EV Battery Cooling Plates market develops in line with broader industry shifts. Over recent years, transitions such as Adoption of Advanced Materials and Integration of Smart Technologies have redefined priorities across the Battery sector, influencing how the EV Battery Cooling Plates market evolves in terms of demand, applications and competitive dynamics. These transitions highlight the structural changes shaping long-term growth opportunities.
01

Adoption of Advanced Materials

The accelerating adoption of advanced materials in EV Battery Cooling Plates is reshaping EV thermal management from both a performance and value-creation standpoint, with this transition projected to add $1 billion to market growth by 2030. Lightweight, high-conductivity aluminum and copper cooling plates are enabling more efficient battery cooling systems, supporting higher energy densities, faster charging, and longer battery life across the electric vehicle battery pack. By reducing overall vehicle weight, these next-generation liquid cooling plates directly enhance driving range and system reliability, reinforcing the strategic importance of material innovation in EV powertrain design. As automakers and battery manufacturers prioritize compact, high-performance thermal solutions, demand for engineered cooling plate materials is set to intensify, structurally elevating the EV Battery Cooling Plates market and upstream metals supply chains.
02

Integration of Smart Technologies

The integration of smart technologies is significantly reshaping the EV battery cooling plates industry by enabling precise and adaptive thermal control. Intelligent cooling plates now incorporate sensors, control units, and software algorithms to monitor individual battery cell temperatures in real time. This transition improves battery efficiency, safety, and lifespan, especially during fast charging and high load driving conditions. The impact extends to associated industries such as automotive electronics, sensors, and battery management systems, where demand for integrated hardware and software solutions is rising. Tier-one suppliers are developing smart thermal modules that combine cooling plates with digital monitoring, while data driven thermal management supports predictive maintenance and improved vehicle reliability. These advancements are accelerating innovation across the EV supply chain and strengthening cross-industry collaboration.