Mechanical Battery Testing
Validating Structural Integrity and Fail-Safe Behavior under Extreme Force.
What we Do
Dynamic Deformation
Simulating High-Impact Crash Scenarios
In this phase, we simulate crash scenarios through sudden, high-intensity force application. This allows us to assess the fail-safe behavior of the cell and the overall enclosure integrity when subjected to the violent energy of a vehicle impact. This data is vital for engineering protective housings that prevent catastrophic internal damage during a collision.
Insights: Validates the structural durability of the cell casing and the effectiveness of internal safety disconnects under sudden deceleration.
Nail Penetration
Targeted Initiation of Internal Faults
This test involves the targeted initiation of an internal short circuit to analyze the resulting thermal response. By penetrating the cell, we validate the robustness of safety mechanisms against thermal propagation, ensuring that a single-point mechanical failure does not escalate into a system-wide fire.
Insights: Provides a definitive "worst-case" thermal signature, allowing engineers to refine propagation barriers and venting strategies.
Quasi-Static Deformation
Determining Mechanical Load Limits
Unlike high-speed crashes, this test utilizes slow compressive loading to determine the mechanical load limits of the cell structure. By observing the deformation behavior under gradual pressure, we identify the exact point of structural failure and the resulting electrical reactions, which is critical for understanding the safety margins of the battery pack.
Insights: Maps the force-displacement curve of the cell, identifying the threshold where mechanical deformation leads to internal short-circuiting.
Customer-Specific Mounting Analysis
Optimizing Module Integration and Assembly
Successful integration requires understanding how external physical factors affect internal performance. This investigation looks at the effects of clamping forces and assembly tolerances on cell performance. This data is used to optimize module integration, ensuring that mounting pressure remains within a range that maximizes both longevity and electrical efficiency.
Insights: Establishes the ideal clamping pressure to prevent "breathing" issues while avoiding excessive stress on the cell's internal chemistry.
Main Testing Areas
Other Tests we specialize in
ELECTRICAL BEHAVIOUR
Battery performance hinges on formation, cycling, and thermal management. Use impedance spectroscopy for aging. Test cells up to 10 V and 300 A.
STRUCTURAL INTEGRITY
Boost energy density, assess crush and penetration, measure impact at 100 kHz, and capture CT deformation plus 6400 fps video.
THERMAL Testing
Battery safety involves abuse testing, failure-propagation prevention, temperature and heat-flux analysis, and environmental ranges from 0 °C to 70 °C.
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EXCLUSIVE PARTners
STRONG COLLABORATIONS
FOR YOUR SUCCESS
Through our renowned partner network, including TÜV Rheinland and RWTH Aachen University, we ensure access to cutting-edge testing technologies and industry-leading expertise.
Our 2,000 m² test facility, equipped with state-of-the-art infrastructure, offers a broad range of testing capabilities to enhance the performance and safety of battery cells and modules — including modules weighing up to 1,500 kg and power up to 1000 V.
INSiGHTS
INSiGHTS FROM OUR WORK
Whether planning and creating reproducible test standards or developing a customized test bench design – our experience spans from component-level analysis to large-scale validation. Discover our work in individual projects.
Success Stories around the globe
WHERE WE
DELIVERED IMPACT IN Practice
From battery testing and compliance to BMS development and operational support, our solutions are designed to work in the real world. By combining proven engineering methods with hands-on project experience, we help our partners reduce complexity, meet standards with confidence, and accelerate time to market.
OTHER OFFERS
DISCOVER WHAT WE OFFER BESIDES OUR TESTING SERVICES
BATTERY Compliance
We ensure your batteries meet all compliance standards for safety and performance.
OPERATIONS & TRAINING
We empower your team with comprehensive training and operational consultation for battery technology and energy storage solutions.
BMS SOLUTIONS
We offer a wide range of Li-Ion battery solutions and Battery Management Systems for various industries.
FAQ
Find answers to your most pressing questions about battery testing services.
Comprehensive testing is the only way to verify the safety, performance, and lifetime of a battery. PEM Motion provides tailored test programs designed to meet the specific requirements of both prototype and series production projects.
We conduct electrical, mechanical, thermal, and safety-related tests. This includes cycle life testing, fast-charging tests, abuse testing, and thermal management evaluations.
Yes. Our experts help analyze test data and translate it into actionable recommendations. This not only saves valuable development time but also reduces unnecessary design iterations.
Timelines depend on the type of test. Thanks to our flexible laboratory infrastructure and strong partner network, PEM Motion can typically achieve very short lead times. We will always find a good solution, if there are time-critical projects.
Beyond development, testing is essential in production – for example, during end-of-line inspections. PEM Motion supports the implementation of efficient testing processes directly into manufacturing workflows.