Rethinking Thermal Runaway Strategies in Propulsion Battery Systems

The aviation industry is accelerating toward an electrified future. As electric propulsion systems gain momentum, the integration of high-energy lithium-ion battery systems introduces a complex set of safety challenges. Chief among these is the risk of thermal runaway, a dangerous and potentially catastrophic chain reaction triggered by failures within a battery cell.

In response to this urgent safety consideration, the General Aviation Manufacturers Association (GAMA) has released a comprehensive white paper: “Propulsion Battery System Thermal Runaway Design Philosophies.” GAMA’s Lithium Battery Working Group developed this document, representing a collective effort by several industry-leading organizations committed to safer electrified aviation.

Contributors to this paper include: Aircraft Electronics Association, BETA Technologies, CAE, Elisen, EP Systems, H55, MagniX, Martin Solutions, and Vertical Aerospace.

Each of these companies brought valuable expertise across battery design, manufacturing, integration, flight operations, and certification. Martin Solutions is proud to be among the contributors and to support this industry-wide effort to reimagine how thermal runaway risk is understood and managed.

The paper challenges the long-standing certification focus on containment, such as that required by FAA standard DO-311A. While containment remains necessary, it is no longer sufficient. Designs that reduce the likelihood of thermal runaway through improved chemistry, robust architectures, better integration, and high-quality production should be credited in certification strategies. The current containment-only focus does not fully reflect today’s technical capabilities and may inadvertently discourage safety improvements.

Instead, the paper presents a performance-based, multi-layered approach to battery safety. This includes risk identification at the cell level, quality control during manufacturing, validated design integration, and operational safeguards. It also introduces concepts like the N+1 failure scenario to test the effectiveness of propagation resistance and system-level mitigation strategies under credible worst-case conditions.

To support this framework, the paper outlines the use of structured planning tools—specifically the Battery Cell Manufacturing Plan (BCMP), Engineering Management Plan (EMP), and Life Management Plan (LMP). These documents provide a comprehensive and traceable approach to lifecycle safety, encompassing design assurance, configuration control, and continued airworthiness requirements.

Equally important, the paper calls for deeper collaboration between regulatory agencies and industry. While both the FAA and EASA are developing guidance for electric propulsion systems, significant gaps and inconsistencies remain. The authors encourage regulators to collaborate with industry in developing harmonized standards that reflect both operational realities and technological innovations.

Drawing on successful models like the AGATE program, the paper envisions a path where regulators, manufacturers, and standards organizations share test data, co-develop certification methodologies, and build a foundation of confidence. This approach will not only improve safety but also speed the deployment of cleaner, more capable aircraft.

At Martin Solutions, we believe that electrification will define the next era of aviation. Our contribution to this white paper reflects our commitment to safety, collaboration, and engineering excellence. Together with our industry peers, we’re helping ensure that the future of flight is not just more sustainable, but also safer by design.

The full white paper is published by the General Aviation Manufacturers Association (GAMA) and is available for reference in the attachment to this post. We invite stakeholders across industry, certification bodies, and government to engage with our insights and help shape the future of propulsion system safety.

Propulsion Battery Systems Thermal Runaway Design Philosophies.pdf

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