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Measuring flame lengths and areas from turbulent flame flares developing from lithium-ion battery failures is complex due to the varying directions of the flares, the thin flame zone, the spatially and temporally rapid changes of the thermal runaway event, as well as the hazardous nature of the event. This paper reports a novel methodology for measuring heat release rate from flame flares resulting from thermal runaway of electric vehicle lithium-ion modules comprising eight 56.3Ah lithium nickel manganese cobalt (NMC) pouch cells using digital cameras and a newly developed numerical code to process the distortion of the flame size based on distance, direction, and shape. The model is tested with a set of experiments using lithium-ion battery packs and validated with a reference set of measurements using calibration boxes, a method commonly used in the reconstruction of flame areas. The experiments showed …