Battery safety testing

Battery testing to current and emerging standards

Batteries are being used in a growing range of applications such as transportation, renewable energy, grid storage, grid balancing, backup applications and uninterruptible power supplies (UPS). The safety and reliability of electric cars, rail and marine applications and aerospace transportation depends on the quality of its batteries. Battery safety and reliability is also a key concern for the renewable energy industry, which utilises a wide selection of technologies for solar energy storage and other applications.

How can we help you?

Our battery testing services are applicable to an extensive range of applications such as electric vehicles, stationary batteries, rail and marine applications, 2-wheel vehicles, grid storage, grid balancing, backup applications, uninterruptable power supplies (UPS), e-bikes, off-road and aerospace.

Battery lifecycle testing

Verify how long a battery lasts and demonstrate the quality of the product to customers. Our tests include cycle life testing, battery environmental cycle testing and battery calendar life testing.

Battery abuse testing

Simulate extreme environmental conditions and scenarios to test your battery beyond its limits (download Infosheet to learn more). Our range of tests includes but is not limited to:

  • Nail penetration
  • Overcharge / over discharge
  • Short circuit
  • Thermal stability
  • Cycling without active cooling
  • Crush / crash
  • Drop
  • Fire
  • Immersion
  • Gas analysis

Battery performance testing

Demonstrate the efficiency of batteries. Our experts can customise testing programs to suit specific customer requirements such as performance testing under various climatic conditions.

Battery environmental testing / Battery durability testing

Demonstrate the quality and reliability of your battery. Our tests include vibration, shock, EMC, thermal cycling, corrosion, dust, salt and humidity tests.

Battery transport testing

Ensure your batteries can be transported safely. We conduct tests for the United Nations requirements (UN 38.3) for the safe transportation of lithium batteries.

Dynamic impact test for electric vehicle batteries

A dynamic impact test 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. The tests are conducted at our crash test facility, which utilises impactors with variable mass and geometry.

Batteries are tested at all levels, with tests that cover investigations such as electrical, chemical, corrosive, mechanical and abuse. The standards that we test to include, but are not limited to:

  • DOE/ID-11069
  • DOE/ID-11173
  • IEC 62660-1/2
  • IEC 62133
  • ISO 12405-1/2
  • SAE J2464
  • SAND 2005-3123
  • SBA S1101
  • UN 38.3

TÜV SÜD formulated and issued the standard PPP 59034A:2014 for RESS (Renewable energy storage Systems) ahead of international standardisation organisations aimed at helping customers bridge gaps in current RESS standards.

Why choose TÜV SÜD

TÜV SÜD is the trusted battery testing expert. Our holistic approach and commitment to safety will optimise the reliability of battery and other energy storage devices products. We are known as a neutral and independent third-party technical service provider, with a focus on delivering value to stakeholders rather than shareholders.

Through our expanding network of laboratories throughout North America, Germany, China, Korea and Singapore, we are ready to serve the needs of customers. This global testing network provides the full range of testing services and validation planning. Out interdisciplinary expertise will add value to your product development and you can also rely on our global network of experts for international market access and in-country experience.

Our laboratories are fully equipped to support the following tests:

Performance testing

  • TÜV SÜD has cell and pack channels that can perform testing of hybrid and electric car batteries, modules and cells.

    Abuse testing, examples:

  • SAE J 2464
  • US Freedom car
  • UN38.3
  • IEC 62660
  • Customised tests

Environmental tests

  • Thermal shock
  • Temperature cycling  -55°C to +140°C
  • Altitude simulation (UN38.3)
  • Dust
  • Humidity
  • EMC
  • IP testing
  • Roll over test
  • SO 16750

Special environmental tests

  • Exposure to harmful gases
  • Chemical exposure
  • Salt water immersion testing of packs up to 3m length

Transport testing

  • Environmental tests according to UN 38.3


White paper

Safety of Lithium-ion Battery Systems

Read more about testing of potential effects of internal battery fires on electric vehicles and their intended occupants.

Learn more

Battery abuse Battery abuse
White paper

Designing Li-ion abuse tests

Find out the gaps in current lithium-ion EV battery standards

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A second life for lithium-ion batteries A second life for lithium-ion batteries
White paper

A “second life” for lithium-ion battery

Learn more about the current technologies.

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White paper

Lithium battery testing under UN/DOT 38.3

Outlines Lithium battery testing required under UN/DOT 38.3.

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Next Steps