Custom Battery Testing

When our clients are preparing to bring battery-powered products to market, facing performance challenges, or analyzing reported failure scenarios, they need more than pass/fail battery testing: They need a deep understanding of what’s happening inside their battery, how it contributes to risk, and the margins for success and failure. Even if a battery “passes” a test, that’s not always an indication of how well it performed, whether its performance is sustainable, or whether untested factors could still lead to a poor product experience in the market and potential liability risks.

Our Approach

Exponent offers a value-added approach to battery testing that goes beyond pass/fail. Given that a certified battery may pass a test by a matter of degrees, we offer insight-driven analyses that elaborate on how a battery may fail, risks posed by its failure, and if possible, where “graceful product failure” can be engineered. These elements have become increasingly important to product companies, battery manufacturers, and their legal teams in seeking to reduce liability, as well as to consumers whose brand loyalty drives success. We prioritize broad quality metrics in parallel with industry certification standards to help our clients create safe, high-performing products. Exponent’s experience in failure analysis and design evaluation allows us to identify potential weaknesses and design custom battery testing to better understand how a product could fail during use or expected misuse. 

Our multidisciplinary custom battery testing services include:

  • Expertise in batteries of all formats, chemistries, and sizes from implantable medical devices to grid-scale utilities/energy storage
  • Extensive testing capabilities for batteries at every scale, including labs across the United States, Asia, and Europe; a global partner network; and large-format custom battery testing for grid-scale utilities/energy storage, electric vehicles, and more at Exponent’s Test and Engineering Center
  • Custom mechanical testing performed from the battery pack level down to the single battery component level under complex loading scenarios, strain rates, and states of charge
  • Finite element modeling of batteries and battery packs to help battery system mechanical engineers optimize battery enclosure design and predict the mechanical interactions between batteries and products under foreseeable user abuse conditions
  • Testing to understand the margins of a battery’s performance
  • Rigorous application of reasonable use and foreseeable misuse scenarios
  • Re-creation testing to validate failure hypotheses in support of litigation and industrial work