<p>Battery thermal management systems (BTMS) are critical for ensuring safety, reliability, and extended lifespan of electric vehicle (EV) battery packs. With lithium-ion batteries becoming more prevalent in EVs, their temperature sensitivity and risk of thermal runaway demand optimized cooling approaches. These approaches must be well-aligned with the automotive EV supply chain, ensuring that thermal management solutions support production scalability, cost-effectiveness, and compliance with regulatory standards. This review consolidates research on BTMS methodologies, including air-based and liquid-based cooling, phase change materials (PCMs), thermoelectric modules, and hybrid configurations. It assesses the relative strengths, limitations, and challenges associated with integrating these solutions into EV systems and supply chains. The study also addresses key research gaps, such as the need for standardized BTMS methodologies and advanced control algorithms. The findings guide researchers, manufacturers, policymakers, and supply chain stakeholders in refining BTMS toward more robust, scalable, and energy-efficient frameworks. Ultimately, improved BTMS strategies are expected to bolster consumer confidence, enhance EV performance, and contribute to a more resilient Indian automotive EV supply chain.</p> Graphical abstract <p></p>