The increasing popularity of electric two-wheelers has underscored the need for efficient thermal management of Li-ion battery packs, as it is essential for ensuring their optimal performance and safety. This paper presents a detailed study on the application of potting material in combination with air cooling for thermal management in a 3s3p NMC 21700 Li-ion battery pack. The study involved analysing the behaviour of the battery pack through physical testing and validating the findings using simulation with Ansys Fluent 2023 R1 software. The simulation results were then leveraged to predict the battery pack's performance when various potting materials were used. Specifically, the research investigated the impact of thermal conductivity, specific heat, and density on the thermal stability of the battery pack. The outcomes of this study clearly demonstrate the effectiveness of using potting material in conjunction with air cooling to maintain the Li-ion battery pack within the desired temperature range, which is crucial for its reliable operation.In summary, this paper underscores the paramount importance of thermal management in Li-ion battery packs for electric two-wheelers. It offers a comprehensive examination of the combined use of potting material and air cooling, revealing its effectiveness in optimizing battery pack performance and ensuring safety. This research contributes to ongoing efforts aimed at enhancing the performance and safety of Li-ion battery packs in the context of electric two-wheelers.