Battery safety testing

Electric Vehicle Battery Testing for Safety | TÜV SÜD

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.


Standards we test against

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



    IEC 60068

    Environmental Testing

    IEC 62620

    Secondary cells and batteries containing alkaline or other non-acid electrolytes - Secondary lithium cells and batteries for use in industrial applications

     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 16750

    Road vehicles — Environmental conditions and testing for electrical and electronic equipment 

    ISO 20653

    Road vehicles — Degrees of protection (IP code) — Protection of electrical equipment against foreign objects, water and access

     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.
  • 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. More details mentioned below.
  • 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

  • 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.
  • Our partnership with Italvolt at a planned Gigafactory in Italy has helped facilitate technical advisory services such as design review, risk assessment or fire protection services, along with testing solutions, including battery testing, EMC or functional safety, inspection services and certification services like TISAX, IATF 16949 and others.

Get in touch with us for Electric Vehicle solutions for your esteemed organisation.
Email: [email protected]



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.

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