In March 2026, the practical content of EPDM halogen-free flame retardant formulation design and development was officially released. Focusing on the industry pain points in the flame retardant R&D of this material, it provides a full-process implementable practical plan from substrate selection, flame retardant matching, process control to troubleshooting, offering important references for material R&D in new energy, electronics, construction and other fields. EPDM is inherently flammable due to its saturated molecular main chain and poor char-forming property. Halogen-free flame retardancy needs to balance char promotion and gas-phase flame retardancy, while reconciling flame retardant, physical and processing properties, and strictly abiding by RoHS 2.0 halogen-free standards and UL94 flame retardant grade requirements. The researchers pointed out that the substrate should be unextended EPDM with specific Mooney viscosity, ethylene and third monomer content. The flame retardant takes phosphorus-nitrogen and inorganic-char formation synergy as the core, with four types of selection packages for different scenarios, and a practical V0-grade formulation for new energy vehicle battery pack sealing is given. Meanwhile, the key process parameters of mixing and vulcanization are clarified, the quick solutions to common faults such as unqualified flame retardancy and product brittleness are sorted out, and it is emphasized that formulation design should grasp three balances and four key points, providing clear guidance for industry practice. For more information, please click: https://www.tiktok.com/@mia_iota/video/7597717976720149782