Qualitek Labs offers comprehensive EV battery testing services to help manufacturers, OEMs, suppliers, and innovators verify battery performance and meet applicable regulatory requirements. Our testing capabilities cover environmental, mechanical, electrical, and safety evaluations, enabling customers to identify potential risks, improve product quality, and accelerate market readiness.
Our EV Battery Testing Services
Fire Exposure Test
Designed to evaluate how battery systems respond to direct flame or extreme heat exposure, this assessment helps identify risks related to ignition, explosion, thermal instability, and fire propagation. It also verifies the effectiveness of built-in safety mechanisms and protective barriers, ensuring the battery can withstand fire-related incidents without posing undue risks to occupants or surrounding components.
Crush Test
Mechanical compression resulting from collisions, impacts, or structural failures can compromise battery safety and performance. This evaluation determines whether the battery can withstand such forces without experiencing leakage, short circuits, thermal events, or structural damage. The test provides valuable insights into the battery’s ability to maintain its integrity under severe mechanical stress.
Vibration Test
Throughout transportation and daily vehicle operation, batteries are subjected to continuous vibrations generated by road conditions, vehicle movement, and handling. This assessment verifies the durability of cells, electrical connections, mounting systems, and enclosures when exposed to prolonged mechanical stress. It helps ensure reliable performance and structural stability throughout the battery’s service life.
Dewing Test
Rapid temperature fluctuations can create condensation within battery systems, potentially affecting performance, insulation, and safety. This evaluation simulates moisture-forming conditions to determine the battery’s resistance to corrosion, electrical malfunctions, and insulation degradation. The results help manufacturers validate battery reliability in humid and changing environmental conditions.
Thermal Cycling Test
Repeated exposure to varying temperatures can place significant stress on battery materials, seals, and internal components. By simulating alternating hot and cold conditions, this assessment helps identify potential issues related to material degradation, dimensional changes, seal failures, and performance loss. It also provides insights into the battery’s long-term durability under fluctuating environmental conditions.
Chemical Exposure Test
Battery packs may encounter automotive fluids, lubricants, coolants, cleaning agents, and other chemicals throughout their lifecycle. This evaluation determines the ability of battery materials, seals, coatings, and enclosures to withstand chemical exposure without compromising functionality or durability. The test helps ensure reliable performance even in demanding operating environments.
Gravel Bombardment Test
Road debris, loose stones, and gravel can cause damage to exposed battery enclosures during vehicle operation. This assessment simulates repeated impact from such materials to verify the strength and durability of protective structures. It helps ensure that external impacts do not compromise the safety or functionality of critical battery components.
Dust Test
Operating in dusty environments can affect battery performance if contaminants enter the enclosure and reach sensitive internal components. This evaluation assesses the effectiveness of sealing systems in preventing dust ingress under challenging environmental conditions. It is particularly important for vehicles operating in industrial, construction, mining, or off-road environments.
Corrosion Test
Long-term exposure to humidity, salt spray, and corrosive atmospheres can negatively impact battery reliability and lifespan. This assessment measures the resistance of battery housings, connectors, fasteners, and structural components to corrosion-related degradation. The test helps verify long-term durability in coastal, high-humidity, and harsh environmental conditions.
Withstand Voltage & Insulation Resistance Test
Electrical safety is verified by assessing the insulation system’s ability to resist current leakage and withstand high-voltage conditions. This evaluation helps identify insulation weaknesses that could lead to electrical failures or safety hazards. The results assure that the battery system can operate safely and reliably under high-voltage conditions.
Air Leak Test
Maintaining enclosure integrity is essential for protecting sensitive battery components from external contaminants. This assessment identifies potential leakage paths that could allow moisture, dust, or other contaminants to enter the battery pack. It helps verify the effectiveness of seals and enclosure designs, supporting long-term performance and reliability.
Tests Using CCU (Climate Control Unit)
Maintaining enclosure integrity is essential for protecting sensitive battery components from external contaminants. This assessment identifies potential leakage paths that could allow moisture, dust, or other contaminants to enter the battery pack. It helps verify the effectiveness of seals and enclosure designs, supporting long-term performance and reliability.
Thermal Propagation & Thermal Runaway Test
Among the most critical battery safety evaluations, this assessment examines how a battery system behaves when a single cell experiences thermal runaway. It helps determine whether heat, flames, or gas generation spread to neighbouring cells and evaluates the effectiveness of containment measures. The test provides valuable insights into overall battery safety under worst-case failure conditions.
Roll Over Test
Vehicle rollover incidents can expose battery systems to significant mechanical and safety challenges. This assessment evaluates the battery’s structural integrity and ability to remain secure during rollover conditions. It also identifies potential risks such as electrolyte leakage, electrical hazards, enclosure damage, or thermal events that may occur following an accident.
Finger Probe Test
Protection against accidental contact with live electrical parts is essential for user and maintenance personnel safety. Using standardized test probes, this evaluation verifies that battery enclosures provide adequate protection against access to hazardous components. It helps ensure compliance with applicable electrical safety requirements and industry standards.
Battery Cooling Test
Maintaining optimal operating temperatures is crucial for battery performance, safety, and lifespan. This assessment evaluates the effectiveness of the thermal management system in dissipating heat during charging, discharging, and vehicle operation. The test helps verify cooling efficiency, prevent overheating, and support consistent battery performance under varying operating conditions.
Immersion Test
This test assesses the battery’s resistance to water ingress by simulating immersion conditions. It helps verify enclosure sealing, electrical safety, and the protection of internal components from moisture-related damage.
Battery Pack Tear Down Analysis
This test involves the careful disassembly and detailed evaluation of a battery pack to examine its internal components, construction, and overall design. The analysis helps manufacturers, OEMs, R&D teams, and investors benchmark battery designs, identify potential failure points, validate manufacturing practices, and gain valuable insights into overall battery performance, reliability, and thermal management.
Battery Pack Tear Down Analysis
This test involves the careful disassembly and detailed evaluation of a battery pack to examine its internal components, construction, and overall design. The analysis helps manufacturers, OEMs, R&D teams, and investors benchmark battery designs, identify potential failure points, validate manufacturing practices, and gain valuable insights into overall battery performance, reliability, and thermal management.
Key Deliverables
Battery Pack Specification – Detailed analysis of battery specifications, cell chemistry, capacity, voltage, energy rating, and pack configuration.
Cell Configuration Analysis – Evaluation of cell arrangement, series-parallel configuration, module architecture, and interconnections
Mechanical Design Review – Assessment of enclosure design, structural components, mounting arrangements, fastening methods, welding, and sealing techniques.
Electrical Architecture Review – Analysis of busbars, BMS layout, wiring, connectors, electrical schematics, and protection systems.
Cooling System Analysis – Evaluation of thermal management design, cooling plates, coolant flow paths, and heat dissipation mechanisms.
Material & Manufacturing Assessment – Identification of materials, manufacturing processes, joining methods, fasteners, sealants, adhesives, and component quality.
Assembly Sequence Documentation – Step-by-step documentation of battery pack disassembly and assembly methodology.
Engineering Observations & Recommendations – Comprehensive technical findings, benchmarking insights, identified risks, and recommendations for design improvement and product optimization.
Test Standards
- AIS 038
- AIS 156
- UN38.3
- IS 16893
- IEC 62660
- ECE R100
- GB/T 38031-2020
- ISO 12405-4; 2018
- ISO 16750-5:2010
UN38.3 Standard (Transport of Dangerous Goods)
- Altitude Simulation
- Thermal Test
- Vibration Test
- Shock
- External Short Circuit
- Impact
- Overcharge
- Forced Discharge
- Crush Test
- Drop Test
Why Choose Qualitek For EV Battery Testing?
- Comprehensive Testing Capabilities A complete range of mechanical, electrical, environmental, and safety tests under one roof.
- Advanced Testing Infrastructure Modern test facilities equipped to evaluate battery cells, modules, and battery packs under real-world operating conditions.
- Experienced Technical Team Highly qualified engineers and testing professionals with extensive expertise in EV battery validation and safety assessment.
- Compliance-Focused Approach Testing aligned with relevant automotive, regulatory, and industry standards to support certification and market readiness.
- Reliable and Accurate Results Precise testing methodologies and detailed reporting for informed engineering decisions.
- Customized Testing Solutions Flexible test programs tailored to product requirements, application environments, and customer-specific validation needs.