Automotive Battery Safety Testing

Ensure battery safety and reliability with development and validation testing to current and emerging standards

Ensure battery safety and reliability with development and validation testing to current and emerging standards

Why Battery Testing is Important

Battery testing is important because batteries must operate safely and reliably under various conditions without posing any risk to people or property. Proper testing of batteries can help ensure that they meet legal, industry, and manufacturer requirements, as well as improve their performance and lifespan.

Additionally, battery testing plays a critical role in the development of new technologies and innovations, helping companies stay ahead of the competition and meet the ever-changing demands of the market.


  • Improved safety: Battery testing services can help identify potential safety hazards and ensure that batteries operate safely under various conditions, reducing the risk of accidents and injuries.
  • Increased reliability: By subjecting batteries to rigorous testing, manufacturers can identify any potential issues or weaknesses and make improvements to increase the reliability and performance of the batteries.
  • Compliance with regulations: Battery testing services can help ensure that batteries meet legal, industry, and manufacturer requirements, reducing the risk of non-compliance and associated penalties or legal issues.
  • Reduced warranty claims: Comprehensive battery testing can help identify potential issues before batteries are put into use, reducing the likelihood of warranty claims and associated costs.
  • Faster time to market: Reliable and comprehensive battery testing can speed up the product development process by identifying potential issues early on and allowing manufacturers to make improvements more quickly.
  • Improved customer satisfaction: By ensuring the safety, reliability, and performance of batteries, manufacturers can improve customer satisfaction and build trust in their products.

Choose TÜV SÜD

TÜV SÜD is your trusted and neutral third-party technical service provider for battery testing. Our battery testing services help battery and electric vehicle manufacturers comply with regulatory standards and access markets while reducing the risks of costly product recalls. As your trusted partner, we provide solid expertise and deep experience in battery testing to maximize the safety, reliability, performance, and lifetime of your products.

Our holistic approach and commitment to safety ensure the reliability of your battery. Our service portfolio covers battery tests for a host of different uses, from electric vehicles and off-road vehicles to e-bikes, aerospace, rail, and waterborne transport. We also specialize in stationary energy storage systems, grid storage, and uninterruptable power supplies (UPS). With years of international experience, modern test equipment, and highly competent experts, TÜV SÜD is the ideal partner for battery testing across a range of industries, including automotive, rail, consumer goods, aviation, shipping, and medical devices.

We test batteries at all levels, with tests in the electrical, chemical, corrosive, mechanical and abusive domain. Various global standards can be applied to your batteries, which include, but are not limited to:



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


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

Through our expanding network of laboratories throughout North America, Germany, China, Korea, Thailand, Japan and Singapore, we are ready to serve your needs. This global testing network is able to provide services for all types of battery testing and validation planning.

Our interdisciplinary expertise will add value to your product development, and you can rely on our global network of experts for international market access and in-country experience. 

Contact us today to learn more about our comprehensive battery testing services.

Our battery testing services

Battery safety & 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. This helps to find suitable countermeasures early enough in the development and avoid delays in the final phase of development.

Also, 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.


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’re able to show the quality of the product to your customers and prove the efficiency of the battery system.

Also, very high-power profiles can 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 customize the testing programs according to your individual and specific customer requirements. 


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 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 battery tests for the United Nations requirements (UN 38.3) for the safe transportation of lithium cells and batteries. In addition, we provide testing according to several safety standards (such as IEC 62133, UL 1642) and performance standards (for example IEC 61960-3).
  • We test your stationary batteries according to the special requirements towards safety, particularly for the European market, including the Low Voltage Directive (2014/35/EU), the EMC Directive (2014/30/EU) and the Battery Directive (2006/66/EC).
  • 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.

Contact Us


More Than Just Compliance Providing High-Quality Battery Systems in xEVs
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Providing High-Quality Battery Systems in xEVs

Ensure high performance and reliability of innovative battery systems

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New mandatory safety testing requirements for electric vehicle batteries under R100
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UN ECE R100 Requirements For EV Batteries

Understand the new requirements under revision 2 of UN ECE R100

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Designing li-ion abuse tests
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Designing Li-ion abuse tests

Find out the gaps in current lithium-ion EV battery standards and how different test methodologies impact safety performance results

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UN/DOT 38.3 Testing

8 Required Tests According to UN/DOT 38.3

Conduct these 8 tests and comply with UN/DOT 38.3

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