Episode 863

863: Unlocking Tesla's Secrets to Battery Firefighting: An Insider's Story

Published on: 9th October, 2025

Landfill explosions, lithium-ion firestorms, and CIA briefings—today’s guest has seen it all - or so she thought!

Kathleen McCaffery’s illustrious firefighting career includes crawling through rubble in Haiti, leading battalions as one of the first female fire chiefs in North America, and even rewriting Tesla’s global fire safety strategy. This episode takes us into uncharted territory as Tesla recruits a retired firefighter to address global concerns over battery [fire] safety.

Most solar companies are woefully underprepared to interact with firefighting agencies, and that’s increasingly going to create friction and unnecessary limitations.  Kathleen spent her entire career breaking down barriers (when she wasn’t breaking down doors!) and has even been in the situation room of more than a few CIA operation briefs! To say she is battle-tested is putting it mildly. She answered the call to serve the country (CIA) and those in need (disaster relief), but could not have been prepared for the call she received post-retirement that pulled her back into active duty, this time taking her halfway ‘round the world to help solve battery fires in Australia! 

This is one of the most fun and wild conversations we’ve published all year.

Expect to learn:

🔹 The hidden dangers of damaged lithium-ion batteries (and why we don’t just bury them)

🔹 Why the age-old truism “big fire, big water” doesn’t work for Batteries

🔹 How Tesla created a new role just to fix their fire communication gap

🔹 Why every developer needs to build relationships with local fire operators, not just permit offices

From Pentagon rescue missions on 9/11 to training Tesla teams, Kathleen’s insights are not only fun and eye-opening—they’re critical for every solar professional adding batteries to their portfolio.

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About the Podcast

SunCast
Your resource for developing a clean energy or climate tech career
Nico Johnson takes you into conversations with those at the forefront of Renewable Energy.

SunCast gives an inside look into what is happening in renewable energy. From conversations with the biggest Solar Panel manufacturers in the world to the small startups creating the future of renewable energy, such as carbon capture and battery technology breakthroughs.

SunCast is dedicated to providing the knowledge, research, tools and expert guidance you need to understand, grow and be ahead of the curve in the fastest-growing markets in the world.

Featuring over 800 conversations, Nico has interviewed people from Tesla, SolarCity, Trina Solar, Meyer Burger, Conergy, SunEdison, Energy Vault and even the US Government... to name a few. Covering topics such as Solar Power, Wind Energy, Batteries, Electric Vehicles, Carbon Capture, Finance, Hydrogen, and more.

You can watch SunCast on YouTube: https://www.youtube.com/@SunCastMedia

...or view the full archive of SunCast episodes here: https://www.suncast.media/media/podcast