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Automotive Battery Safety Testing

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

Battery Testing Overview

Battery technology is developing at a breath-taking pace. Nevertheless, your customers’ expectations for safety and quality are as demanding as always.

Battery testing addresses these issues by validating the safety and reliability of the batteries used in a growing range of applications. This includes batteries for transportation applications such as electric vehicles, rail, marine and aerospace, but also stationary batteries for grid storage and balancing, backup power applications and batteries for wireless equipment and medical devices.

Why Battery Testing is Important

Batteries must not pose any danger to people, not even under extreme conditions. They should therefore be evaluated thoroughly before being put into use with an effective set of battery tests. The tests ensure that batteries fulfil legal, industry and manufacturer requirements.

Working with TÜV SÜD as an expert partner to ensure the safety, reliability and consequently the quality of your battery type provides multiple benefits for you:

  • Stay ahead of the technological development with experts who are at the forefront of the battery industry.
  • Save time and money with reliable tests that reduce warranty claims, time to market and R&D activities.
  • Work with a single-source provider for testing and certification, supporting you through the entire value chain from component to final product.
  • Obtain battery certification that helps you to gain customer confidence by providing the best quality and safe batteries for various industries. 

expert in testing battery cells, modules and packs

TÜV SÜD is your trusted and neutral third-party technical service provider for battery testing. TÜV SÜD assists battery and electric vehicle manufacturers in meeting battery standards and demands required. 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. This creates greater confidence to fulfill your customers’ expectations, comply with regulatory standards and access markets, while reducing risks of costly product recalls. We support you in a variety of sectors including the automotive, rail, consumer goods, aviation, shipping and medical devices industries.

Our holistic approach and commitment to safety will ensure the reliability of your battery. 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). This versatility, combined with years of international experience, modern test equipment and highly competent experts, makes TÜV SÜD the ideal partner for battery testing.

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.

Our battery testing services

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

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. 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.

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’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. 

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 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.


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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New requirements for electric vehicle batteries

Understand the new requirements under revision 2 of UNECE 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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