Battery safety testing


Ensure EV battery safety and reliability to current and emerging standards

Ensure EV battery safety and reliability to current and emerging standards

TÜV SÜD assists battery and electric vehicle manufacturers to meet standards that fulfil legal, industry and manufacturer requirements. We provide tests at all levels - in the electrical, chemical, corrosive, mechanical and abusive domains, to maximise safety and reliability in the growing range of applications. We provide tests to safety and quality standards including but not limited to IEC 60068, IEC 62620, ISO 12405, ISO 16750 and ISO 20653.



TÜV SÜD test batteries at all levels, with tests in the electrical, chemical, corrosive, mechanical and abusive domain. Our service portfolio covers battery tests for a host of different uses: from electric vehicles and off-road, e-bikes, aerospace, rail and waterborne transport to the extensive field of stationary energy storage systems, grid storage and uninterruptable power supplies (UPS).

  • Battery safety and battery abuse testing
    Testing in extreme environmental conditions and beyond standard operating conditions helps you find out about product risks and enables more accurate risk assessments. Dynamic impact testing simulates a real vehicle accident to determine the true safety performance of the battery when the car body is deformed. TÜV SÜD can perform dynamic impact tests for electric vehicle batteries and provide advice on the optimum test design including impactor geometry.
  • Battery performance and lifecycle testing
    We support you in verifying how your battery is performing against the specification, be it in terms of lifetime or in terms of the power output. Through this, you are able to show the quality of the product to your customers and prove the efficiency of the battery system. Very high-power profiles can also be implemented to validate fast charging or simulate some laps on the race track. Our battery tests include lifecycle testing, battery environmental cycle testing and battery calendar life testing. Our experts can customise the testing programmes according to your individual and specific customer requirements.
  • Battery environmental and durability testing
    We support you in demonstrating the quality and reliability of your battery. This helps you to evaluate the effect of external influences on your battery and prove performance under all circumstances by tests like vibration, shock, EMC, thermal cycling, corrosion, dust, salt and humidity tests
  • Battery mechanical testing
    For li-ion batteries, it is important that they are tolerate to compression and tension in order to minimize risk from damage, short circuit, heat or thermal. At TÜV SÜD, we can support in testing material characteristics (tensile, compression, shear), impact, scratch, abrasion, pressure cyclic, burst and leakage.
  • Battery material testing and chemical analysis
    High-performance materials are increasingly required to meet the needs for high capacity, safety, and long life for li-ion batteries. We can support to perform the test requirements for SoC, RoHS, REACH. Additionally, we can test VOCs, fogging, smell/odor, and flammability to ensure that materials are in high quality and up to certain specifications.
  • Battery certification and global market access
    We support you in ensuring that your batteries can be transported safely and access markets worldwide according to the applicable legal requirements. We conduct approval tests required under ECE-R100.02 and other international standards for the global market access of electric vehicles and support you along the whole approval process.



  • We test batteries at all levels, with tests in the electrical, chemical, corrosive, mechanical and abusive domain:



    IEC 62619

    Safety requirements for secondary lithium cells and batteries, for use in industrial applications

    IEC 62660

    Secondary lithium-ion cells for the propulsion of electric road vehicles

    ISO 12405

    Electrically propelled road vehicles

    ISO 6469-1

    Electrically propelled road vehicles - safety specifications - part 1: on-board rechargeable energy storage system (RESS)

    GB 38031

    Electric vehicles traction battery safety requirements

    GB/T 31484-2015

    Cycle life requirements and test methods for traction battery of electric vehicle

    GB/T 31486-2015

    Electrical performance requirements and test methods for traction battery of electric vehicle

    SAE J2464

    Electric and hybrid electric vehicle Rechargeable Energy Storage System (RESS) safety and abuse testing

    UN 38.3

    Recommendations on the transport of dangerous goods - manual of tests and criteria part III 38.3

    UL 2580

    Standard for safety - batteries for use in electric vehicles

    UN ECE R100

    Uniform provisions concerning the approval of battery electric vehicles with regard to specific requirements for the construction and functional safety



  • 10+ years of global experience and network of labs
    Benefit from our global expertise, local experience and reach through our network of labs for automotive, battery, EMC & wireless and environment testing across North America, Germany and Asia.
  • Comprehensive assessment for charging infrastructure
    Our global experts provide a full range of services for electric vehicle charging infrastructure and systems, from site assessment and selection to the initial testing and certification of charging units, as well as on-site commissioning inspection after installation. We leverage extensive expertise in automotive, infrastructure, battery and alternative energy concepts to help top industry players develop and test e-Mobility technologies.
  • Battery Testing
    With a network of 9 battery testing labs spread across North America, Germany and Asia, including Thailand, we assist you to meet EV battery testing requirements by fulfilling legal, industry and manufacturer requirements, offered at all levels - electrical, chemical, corrosive, mechanical and abusive domains.
  • 360° approach

    Assure safety, marketability and compliance throughout the entire value chain, right from electric vehicle components and systems to batteries and charging infrastructure. 

  • Global Market Access
    Partner with us to meet your local and global testing & certification requirements applicable in target markets, facilitated by globally accredited laboratories (DIN EN ISO / IEC 17025). Also gain confidence with us, as we support your requirements for approval tests under ECE-R100.02 and other international standards of all vehicle categories, systems and components.

  • Some key milestones with stakeholders
    - Through a recently signed MoU with ComfortDelGro Engineering we have jointly developed a training programme that aims to upskill automotive technicians on the safe handling of high voltage systems in electric and hybrid vehicles. This partnership aims to set industry standards and enable more skilled technicians to be readily available as Singapore works towards a more sustainable future.

    - Our strategic partnership with Contemporary Amperex Technology Co. Limited (CATL) has further enhanced our expertise in battery testing & certification, functional safety and other areas to provide services that will mitigate potential risks and help achieve steady & safe development of the global new energy industry.

    - Our commitment to sustainability has been further cemented through a pilot project at Microvast GmbH, where we have developed a climate-friendly and sustainable approach, covering the entire product cycle of battery production. Using SDGs as a benchmark, our teams have identified specific indicators and opportunities for improvement of sustainability through regular tracking and monitoring.

For more info on EV battery testing

We offer EV battery testing services to ensure that your products meet the highest levels of quality and safety while ensuring compliance with relevant standards and regulations.

Contact us