The National Laboratory of the Rockies (NLR) and industry partner KULR Technology Group have received NASA’s 2025 Invention of the Year Award for an internal short-circuit device (ISC-D) designed to improve battery safety testing. The device allows researchers to intentionally trigger battery failures in controlled laboratory settings, addressing a longstanding challenge in battery development for aerospace applications.
Battery failures pose particular risks in space missions, where isolation and harsh conditions amplify potential consequences. The ISC-D technology enables scientists to study how lithium-ion cells respond to internal short circuits, which can occur from microscopic manufacturing defects such as dust particles. These internal failures can trigger thermal runaway—a chain reaction of venting gas and extreme heat that spreads from cell to cell and can potentially disable entire spacecraft systems.
The device consists of three layered metal discs separated by a specially formulated wax blend that melts at 57 degrees Celsius, allowing the metal components to make contact and trigger a controlled short circuit. This approach replicates internal failure modes that external abuse tests, such as nail penetration or crushing, cannot adequately simulate. Researchers spent years perfecting the wax formulation, ultimately combining paraffin and microcrystalline wax to achieve the necessary balance of flexibility and rigidity for reliable, repeatable testing.
The collaboration between NASA and NLR dates to 2010, when the teams began developing the foundational ISC-D concept. KULR has since advanced the technology by offering pre-assembled battery cells with the ISC-D already implanted, streamlining testing processes for commercial applications. The technology is now employed by more than 80 companies, including SpaceX, Tesla, Toyota, and Volkswagen, for testing batteries in commercial aircraft, satellites, and vehicles.
According to NASA officials, nearly all battery designs for manned spacecraft applications have been validated using ISC-D testing to ensure they can withstand internal short circuits without experiencing cascading failures across the battery pack. The invention represents a significant advance in battery safety verification for high-stakes applications.