Teaser_Reproducibility

 

Advanced Battery Testing

Safe. Reliable. Proven.

 

In an industry shaped by rapid innovation, regulatory pressure, and growing safety concerns, the demands on battery testing have never been higher. Whether you're developing next-generation battery systems like solid state batteries for e-mobility, testing modules before shipment, or evaluating the residual performance of second-life storage systems — advanced environmental testing is essential for ensuring long-term performance, functional safety, and market approval.

From R&D labs to end-of-line testing and second-life qualification, batteries are subjected to a wide range of environmental conditions. Thermal stress, vibration, humidity, and mechanical shock can all influence the integrity, lifespan, and safety of a battery system. The risk of fire, thermal runaway, and explosive events must be assessed and mitigated through reliable, controlled, and repeatable testing protocols.

Diagram for integrated explosion protection. From preventing build-up of hazardous explosive atmospheres to limiting the effects of an explosion.
As energy density increases, so do the hazards. That’s why the EUCAR Hazard Levels and ATEX guidlines play an important role in defining safety requirements in battery testing environments. Especially when testing large-format lithium-ion or solid state batteries, selecting the right test infrastructure is about more than performance — it’s about protecting your product, your people, and your lab environment.

Weiss Technik is one of the world’s leading providers of climate, temperature, vibration and more environmental test systems. We offer battery testing solutions that meet the most demanding industrial and regulatory requirements. Backed by decades of experience in battery testing, we offer manufacturers, suppliers and external test laboratories customized solutions for the entire life cycle of batteries..

Whether it is a single test chamber, a complete lab or a container-based solution, we know what matters. We take your infrastructure, your testing requirements and all safety-relevant aspects into account and support you from concept to commissioning. After installation, our service team is also there for you with fast and reliable support for maintenance and calibration.

Experience how our customer FEV brings battery testing to life. From environmental and mechanical stress tests to performance testing of battery cells, modules, and packs this facility demonstrates the full range of possibilities enabled by Weiss Technik systems. With test temperatures from –40 °C to +90 °C and powered largely by a 12,000 m² photovoltaic system, it sets new standards in both capability and sustainability.

 

Full EUCAR safety compliance – From gas detection to tertiary explosion protection


Custom configurations – From compact test cabinets and walk-in chambers to mobile, containerized solutions and complete state-of-the-art test facilities


Flexible test conditions – Covering extreme temperature ranges, fast temperature changes, humidity, and combined testing (e.g. temperature + vibration)


Proven expertise – Thousands of installations worldwide, including leading automotive OEMs and accredited test labs


Global service & support – Local contacts, fast spare parts delivery, and expert assistance wherever you are 

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Discover how the CARL Research Center at RWTH Aachen is revolutionizing the aging mechanisms and lifespan of batteries. Equipped with chambers from Weiss Technik over 120 scientists are optimizing the battery lifespan from the molecular level to complex systems.

This exclusive technical brief reveals:

  • Exclusive insights into the battery testing laboratory at RWTH Aachen University
  • Trends and challenges in optimizing energy storage for electromobility
  • Transformative testing technologies driving battery innovation

 

Climate Testing

Validating Performance, Safety and Compliance under Thermal und Humid Stress

 

Lithium-ion batteries are exposed to a range of environmental stresses throughout their lifecycle. Climatic testing replicates these real-world conditions including cold starts, high ambient temperatures during charging and seasonal temperature cycling. These scenarios are essential for validating battery performance in automotive, aerospace, electronics and stationary energy storage systems.

Temperature cycling involves repeatedly exposing cells to alternating high and low temperatures to simulate environmental fluctuations and identify potential issues like material fatigue, seal degradation, or electrode delamination.

Long-term stress testing subjects batteries to extended charge-discharge cycles or constant load over time to assess aging behavior, capacity fade, and safety margins. 

Testing lithium-ion batteries under thermal stress involves significant safety risks, including thermal runaway, gas release, fire, and even explosion.

To mitigate these hazards test systems should comply with EUCAR Hazard Levels and ATEX guidelines. Features such as additional door interlocks, fire detection or purging systems contribute to safe testing for employees and infrastructure.

Battery safety testing is governed by strict standards such as UN 38.3 for transport, IEC 60068 for durability and reliablility, and UL 2580 for EV battery safety. In addition, OEM-specific protocols often impose further requirements. Test systems must ensure reproducibility, traceability and full compliance under all conditions.

 

See how Volkswagen uses a drive-in climate chamber from Weiss Technik to test complete electric vehicles under controlled temperature and humidity conditions. The setup allows full-scale thermal validation, including battery performance, vehicle electronics and safety systems under real-world stress scenarios.

Extreme temperatures. Rapid cycling. Long-term stress conditions. If your battery tests are to meet today’s performance and safety requirements, your environmental simulation needs to be as advanced as the batteries themselves.

Weiss Technik offers targeted solutions for these challenges. Our climate and temperature chambers are engineered to meet the demands of modern battery testing. Whether you need dynamic environmental control, safety options, or compact systems for parallel testing in tight lab environments our ClimeEvent, TempEvent and LabEvent provide reliable test conditions, high efficiency, and easy integration into your lab infrastructure.

The ClimeEvent and TempEvent series are designed to meet the demanding requirements of environmental testing in battery development and validation.

They offer precise thermal control, fast temperature changes, and full climate regulation where needed. Features like automatic water refill, a real-time status bar (green = running, orange = warning, red = fault), and remote access via optional S!MPATI software ensure uninterrupted test operation even over weekends.

Key benefits:

  • Wide temperature range from –50 °C to +180 °C
  • Consistent, reproducible testing even at fast ramp rates (up to 25 K/min)
  • Reliable long-duration runs with automatic water refill and live system status
  • Unattended operation via remote monitoring and push notifications with S!MPATI
  • Certified safety up to EUCAR Hazard Level 7
  • Full compliance support with absolute humidity control and documentation via S!MPATI
  • Energy-efficient operation and compliant with EU refrigerant regulations thanks to  CO2 refrigeration system

Perfect for:
Battery cells, modules, electronics, and system components in R&D and quality assurance.

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The LabEvent chamber is designed for efficient testing of multiple battery cells on a small footprint. Its compact size allows parallel testing on several levels, making it ideal for high-throughput scenarios, batch validation, and screening applications. With precise thermal control and uniform temperature distribution, LabEvent ensures reliable and consistent results.

Key benefits:

  • Smallest footprint in its class ideal for space-limited lab environments
  • Parallel testing of battery cells on multiple levels
  • Supports constant climates and selected alternating temperature profiles
  • Wide temperature range from -40 to +130°C
  • Integrated safety features for secure operation
  • Quick lab integration with 400 V power connection
  • Energy-efficient operation and compliant with EU refrigerant regulations thanks to  CO2 refrigeration system

Perfect for:
Battery developers, screening labs, and long-term cell testing under stable environmental conditions

Configure now

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Case Study: 22 Climate Test Chambers for VW Group 

Space-optimized testing of lithium-ion packs with Hazard Level 6 safety

At the Volkswagen Group’s Battery Systems Competence Centre in Braunschweig, Germany, 22 climate test chambers were implemented to enable temperature and climate testing of large-format lithium-ion batteries. The solution includes 18 standard chambers and 4 special versions with advanced functions like high-temperature cycling. 

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(c) FEV

Case Study: Efficient Temperature Testing at FEV

10 custom-built temperature chambers for the world’s largest high-voltage battery test center

FEV Group required a scalable, high-performance solution for lithium-ion battery testing at their 15,500 m² facility. Weiss Technik delivered ten individually controlled, modular temperature chambers equipped with safety technology up to Hazard Level 4. Integration into the site’s central cooling system and staged delivery enabled parallel lab operation during construction.

 

Thermal Shock Testing

Validating Structural Integrity and Safety under Rapid Temperature Change

 

Lithium-ion batteries must withstand sudden and extreme temperature changes whether during transport, high-altitude flights, or in rapid environmental shifts. Thermal shock testing replicates these conditions to uncover mechanical and thermal weak points before they become safety risks.

Shock testing is often part of stress and reliability testing during product validation phases for applications in aviation, defense, and global logistics where batteries may be exposed to abrupt environmental transitions.

These tests also help to reveal weaknesses that would have remained invisible under normal test conditions. Temperature transitions, for example from –40 °C storage to +80 °C, create internal stresses that affect housings, seals, welds, and terminals. Even small deformations in modules or packs can lead to cracks, seal failure, or electrical disconnection.

As battery formats grow in size and energy density, the safety demands during thermal shock testing increase significantly. The combination of high thermal mass, reactive materials, and aggressive test parameters poses substantial risks, including gas release, thermal runaway, fire, and even explosion. To mitigate these hazards, test systems must be equipped with certified safety components. 

 

Thermal shock testing must comply with a range of international standards that define how temperature transitions are applied, how long the test conditions must be held, and what stability is required throughout the cycle.

Key regulations include IEC 60068-2-14, which specifies the basic test procedures, UL 2580 for electric vehicle battery safety, and LV 124 K13, which sets strict requirements for thermal shock in the automotive sector. In many cases, OEMs demand custom profiles on top of these baseline standards.

See how the Volkswagen validates battery durability with air-to-air thermal shock testing. In their lab, large battery packs are exposed to sudden temperature transitions by moving them between hot and cold zones..

Thermal shock testing often plays a crucial role in assessing the structural integrity, thermal behaviour and long-term reliability of battery cells, modules and packs. With rapid temperature transitions, critical load conditions can be reproduced, helping to uncover hidden weaknesses and failure risks early in the development process.

Weiss Technik offers specialised systems for both air-to-air and air-to-liquid shock tests. Our solutions fulfil the requirements of automotive and industrial standards and support reproducible, safe and efficient testing.

Air-to-Liquid Thermal Shock Testing 

Designed for ice water immersion testing, the ShockEvent IW enables direct transfer from high-temperature airspace to cold water. Ideal for validating sealing integrity and mechanical durability under rapid stress, as defined by LV 124 K13, ISO 16750-4 and related standards.

Key benefits:

  • Automated air-to-water transfer
  • Test chamber temperatures up to +180°C
  • Quick and easy programming of hold times
  • Suitable for large-format lithium-ion batteries
  • Compact system design with factory pre-commissioning
  • CO₂-based cooling technology included as standard from 2025

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Air-to-Air Thermal Shock Testing for Fast-Cycling Tests

The ShockEvent system exposes test specimens to abrupt temperature transitions between –80 °C and +220 °C. Unlike thermal cycling, this method reveals failures that only occur during rapid material expansion and contraction — such as cracks, leaks or bond breaks. 

Available with vertical lift or damper system and designed for high throughput and low maintenance.

Key benefits:

  • Fast air-to-air transitions: –80 °C to +220 °C
  • Two system variants: lifting or fixed space
  • Integrated volume compensation to prevent icing
  • Over 1,000 cycles possible without defrosting
  • Ideal for battery cells, modules and electronics

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Case Study: Splash Water Testing

To meet the demanding requirements of standards like VW 80000:2017 and LV124 K-12, a mobile splash water system was integrated into FEVs battery testing center. 

The system can be used in temperature and climate chambers where lithium-ion batteries are heated to operating temperature and then repeatedly surge with 0 to 4°C cold water. According to the test standard, the water contains ultrafine Arizona dust. It offers a highly flexible option for extended shock testing.

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Case Study: Water Shock Immersion Test for EV Batteries

At a leading international certification body, Weiss Technik delivered a large-scale immersion shock system for lithium-ion batteries. The system enables standard-compliant tests according to LV 124 K13, ISO 16750-4 and ISO 20653.

With a controlled immersion of up to 1,200 kg test specimens into a near-zero-degree saltwater bath, the solution is designed for extreme thermal shock cycles. Thanks to a custom lifting platform and integrated safety features up to Hazard Level 6, it supports realistic testing of operational battery systems. 

 

Vibration Testing

Validating Battery Performance and Safety Under Vibration

 

Vibration testing is critical to confirm the mechanical durability and electrical stability of batteries during transportation, vehicle operation, or industrial use. Vibrations can cause contact loss, cell displacement, solder joint fractures or insulation damage - sometimes insidiously. These faults affect both the electrical safety and the mechanical integrity of the battery. For modular systems in particular, it is crucial to test material and fastening concepts under continuous load.

Vibration alone rarely tells the full story. In real-world use, mechanical loads interact with temperature and humidity. That’s why combined vibration and climate testing is often required, especially for mission-critical applications such as electric vehicles, aviation systems, or industrial machinery.

The challenge lies in reproducing these stress factors precisely and safely in one synchronized test cycle, especially with large, energy-dense battery formats.

As batteries grow in size and capacity, the potential hazards increase. High test loads, active BMS systems, and thermal stress add to the risk. Systems must include secure mounting options, monitoring equipment, and protective features that match the hazard level of the battery type.

At the same time, test setups must allow real-time monitoring of battery behavior: voltage, current, surface temperature or CAN signals. This requires robust data integration that functions reliably even in high-vibration environments.

Before any lithium battery can be shipped, it must pass vibration tests according to UN 38.3. These involve sweeping through frequencies from 7 to 200 Hz across three perpendicular axes, under defined acceleration and dwell times. This test is a legal requirement, not a formality — and it demands precise documentation and traceability.

Additional standards such as IEC 60068, SAE J2380, or OEM-specific profiles may apply depending on your application and market. Reliable test results depend on a tightly controlled, compliant test setup.

At Volkswagen’s Battery Testing Center, a multi-axes shaker simulates 15,000 km of driving within a single week under combined vibration, temperature, and charging cycles. The system exposes high-voltage batteries to dynamic road stress, from cobblestones to highway vibration, while simulating extreme climate conditions.

Battery packs in electric vehicles are exposed to intense mechanical and thermal stress. Our vibration test chambers are built to meet these exacting demands. From standardised combined climate-vibration setups to fully customised systems, we help you simulate real-world conditions with precision and repeatability even for large and complex battery assemblies.

ShakeEvent is our standardized solution for vibration testing with controlled temperature and humidity. It is ideal for testing battery cells, modules, and smaller packs under combined environmental and mechanical conditions. The chamber supports seamless integration with electrodynamic shakers and enables synchronised operation of vibration and climate profiles.

Key benefits:

  • Compact footprint with large internal volume
  • Temperature range from –65 °C to +150 °C
  • Seamless integration with various shaker types
  • Space-saving design requieres no supports near the shaker
  • Suitable for cell, module, or full-system testing

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For high-mass battery systems and advanced test requirements, Weiss Technik develops fully customised vibration test chambers. Systems can accommodate test objects with volumes of up to 1.3 tonnes. Every solution is tailored to your specific setup including shaker type, control architecture, and safety requirements.

Key benefits:

  • Customised test solution
  • Capable of large-scale battery packs with active BMS
  • Flexible integration with your preferred shaker system
  • Adapted to your safety requirements and hazard level

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Case Study: High-Force Vibration Testing for EV Battery Packs

Custom vibration test systems with Hazard Level 5 protection.

In a leading automotive test center in the US, Weiss Technik delivered three high-performance vibration test chambers for battery packs weighing up to 1.3 tons. Each system combines temperature control from −55 to +90 °C with powerful shakers (up to 350 kN), a modular safety system, and future-proof refrigerants. 

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Case Study: 350kN Vibration Test Chamber for FEV

Road stress simulation under thermal load.

At FEV’s battery test center, Weiss Technik delivered a custom-built vibration test system for complete lithium-ion battery packs. The system integrates a 350 kN shaker with a 21 m³ stainless steel chamber and a motorised traversing unit for vertical and horizontal shaker modes. The setup enables precise simulation of road stress and temperature profiles from −40 to +100 °C. Safety features comply with Hazard Level 4 and ensure reliable testing of heavy battery assemblies up to 3,000 kg per m².

 

Destructive & Battery Abuse Testing

Controlled Destruction to Validate Battery Safety

 

Destructive battery testing deliberately pushes lithium-ion cells, modules, or packs beyond safe operating limits. These tests are critical for understanding battery behavior in worst-case scenarios including internal short circuits, thermal runaway, overcharging, and mechanical damage. Insights gained during destructive testing help improve product safety, support transport certifications, and protect users and emergency responders.

Abuse testing covers mechanical, thermal, and electrical stress to evaluate battery safety.

Mechanical tests simulate damage from impacts or intrusions, such as nail penetration or crushing. These assess how physical deformation or internal short circuits affect battery safety.

Thermal tests expose batteries to extreme ambient temperatures, often beyond 200 °C, to provoke thermal runaway through controlled heat transfer.

Electrical tests recreate critical faults like external short circuits or overcharging. These trigger rapid heating and help evaluate the battery’s electrical fail-safety under extreme stress.

Destructive battery tests end in critical events such as fire, gas release, or explosion. For this reason, they were often carried out outdoors in remote areas but without the ability to capture consistent, repeatable data.

Modern battery abuse test chambers must ensure maximum safety for people, equipment, and buildings. This requires Hazard Level 7 design, including explosion protection, pressure relief systems, gas extraction, and fire containment. Only then can high-risk tests be performed reliably in a controlled lab environment.

Standards such as UL 2580, IEC 62660-2, and SAE J2464 define clear protocols for abuse testing. These include nail penetration, crushing, overcharge, overheating, and external short circuit.

Propagation tests are increasingly requested by OEMs to verify whether a failing cell can trigger failures in neighboring cells or modules.

Each test type presents unique technical demands. Test setups must allow for precise control of heating, force application, current flow, and environmental isolation.

Discover how the explosion proof chamber handles mechanical, thermal, and electrical abuse tests. This video shows how destructive battery tests are carried out safely in a laboratory environment.

Extreme risks require robust solutions. Our ExtremeEvent chamber is engineered specifically for destructive battery abuse testing in a controlled laboratory environment. It supports mechanical, electrical, and thermal abuse scenarios, including propagation tests, while ensuring the safety of personnel, facilities, and test equipment.

This system is engineered to handle the full spectrum of battery failure scenarios, including thermal runaway, mechanical damage, overcharge, nail penetration, and electrical short circuits.  Its modular design allows you to replace the inner test compartment after extreme reactions ensuring long-term reliability and cost efficiency.

Key Benefits

  • Explosion proof
    Designed to contain fire, pressure, gas, and particle release during destructive battery events.
  • Modular and replaceable test compartment
    Inner test area can be exchanged after severe reactions. Enables long-term use and cost efficiency.
  • Safe testing of cells, modules, and full packs
    Scalable interior allows testing of different battery formats and sizes.
  • Optional high-speed video and gas analytics
    For visual documentation and in-depth analysis of thermal propagation and failure behavior

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Expert Matthias Eydner will guide you through the features and functionalities of the ExtremeEvent. The chamber is built to handle high-pressure events and heat releases, incorporating tertiary explosion protection and is certified by the TUEV institution. Its stainless steel and reinforced design withstands pressures up to 1.5 bar and temperatures up to 650°C.