Thermal Battery Testing
Induction of thermal runaway in a single cell (e.g., via heating mat or nail penetration) to demonstrate propagation prevention at module or pack level.
What we Do
Thermal Propagation
Preventing the Chain Reaction
This test focuses on the ultimate safety benchmark for multi-cell systems: containment. By inducing thermal runaway in a single cell through precise triggers like heating mats or nail penetration, we demonstrate whether your module or pack-level safety barriers can successfully prevent propagation to neighboring cells. This rigorous simulation provides the empirical data required to verify that a localized failure does not evolve into a catastrophic system-wide event.
Insights: This validation confirms the effectiveness of your firewalls and thermal barriers, ensuring the system meets critical safety standards for passenger protection.
Overheating
Establishing Absolute Safety Boundaries
To build a reliable Battery Management System (BMS), you must first understand the hardware’s physical breaking point. We expose test specimens to critical ambient temperatures to determine their absolute thermal stability limits, such as the precise temperature at which separator melting occurs. By mapping these environmental boundaries, we help you define the safe operating window for your specific chemistry and housing.
Insights: These results allow for the precise calibration of BMS safety thresholds, preventing operation in zones that would lead to irreversible material degradation.
Gas Emission Analysis
Chemical Risk Assessment for Venting Events
When a battery enters a fault state, it may release a complex mixture of gases that present toxicity and flammability risks. Our facility conducts qualitative and quantitative analysis of these venting gases to identify their exact composition and evaluate the dangers they pose. This data is essential for engineers designing venting paths, filtration systems, and enclosure integrity to protect both the user and the surrounding environment.
Insights: This analysis provides a complete risk profile of the cell's outgassing behavior, ensuring your safety protocols account for chemical toxicity and flammability.
Cell and Pack Material Testing for Heat Dissipation
Optimizing Cooling Efficiency and Material Performance
Performance longevity is directly tied to how efficiently a pack can shed heat during high-load operations like fast charging or rapid acceleration. We validate the performance of thermal interface materials (TIMs) and overall cooling strategies to ensure that heat is moved away from the cells as effectively as possible. This testing identifies potential hot spots and confirms that your thermal management architecture can maintain uniform temperatures across the entire pack.
Insights: This process benchmarks the real-world thermal resistance of your materials, providing the data needed to optimize cooling flow and extend the life of the battery.
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.