The electric vehicle (EV) revolution demands new materials that address performance, safety, and sustainability imperatives. High-performance polymers are emerging as essential replacements for heavy metals and brittle glass in electric vehicle battery systems, where they offer weight reduction, insulation, thermal management, and fire hazard solutions. This paper explores how high-performance polymers can help enhance EV performance by offering lightweight, high-durability, thermally and electrically feasible alternatives to traditional metals and glass. By the analysis of some of the most significant polymer families, such as polyurethanes, epoxies, and glass-filled nylons. A comprehensive analysis of over 40 peer-reviewed papers, industry reports, and technical standards was conducted to analyze and detail their specific applications in thermal management, electrical insulation, and mechanical protection in high-voltage battery systems. The findings emphasize the key role of polymers in the development of faster, safer, and more efficient electric vehicles.

Electric vehicles, high-performance polymers, high voltage battery systems, thermal management, lightweight materials

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