Electrification is a major growth area for the automotive industry. Batteries and electrical machines are also being used for aerospace, rail and marine applications.

Battery Testing

UTAC conducts hybrid and electric vehicle (EV) battery testing to assess the life of battery cells, modules and packs, determine battery safety in a wide range of situations including crash events, and validate the performance of automotive batteries under a range of environmental conditions.

UTAC operates a state-of-the-art battery life and performance test facility in the UK. It tests all major Lithium-ion chemistries and a range of other chemistries by simulating normal and extreme operating conditions.

These tests include :

  • Pack life and performance testing
  • Cell and module life and performance testing
  • Shock Testing
  • Battery Safety and Abuse, including Battery Drop and Nail Penetration Testing


Our facilities also offer a range of electric machine and inverter tests and provides full vehicle test facilities including the ability to crash EVs and FCVs.

Battery Safety and Abuse Testing Regulations

UTAC offers the full suite of UN38.3, GB/T 31485, and ECE R100 battery tests. It can also offer a number of routes to certification for Regulations including 100, 10, 85 and 136. We also conduct most other types of battery safety and abuse testing.

Our battery safety and abuse testing area has been specifically set up to accommodate destructive battery testing with sufficient safety measures.

cell battery

UTAC can test most battery chemistries, even at prototype level. Battery safety and abuse testing capabilities for cells, modules and packs include:

  • Battery Drop Tests
  • Battery Corrosion Tests
  • Battery Nail Penetration tests
  • Immersion Tests
  • Turnover and Coolant Flooding
  • Fire Resistance Tests
  • Over-Discharge Tests
  • Over-Charge Tests
  • Over-Temperature Tests
  • Short Circuit Tests
  • Thermal Propagation Tests
  • Thermal Shock and Cycling Tests
  • Battery Mechanical Crush, Impact and Shock Tests
  • Altitude Tests
  • Vibration Tests

Battery Shock Test Capabilities

UTAC can test battery cells, modules and packs up to 2m x 1.4m x 1.5m indoors and up to any size outdoors.
We support battery shock testing to a range of standards.

UTAC’s state of the art Battery Test Facility consists of 12 EV battery cycling climatic chambers (soon to be increased to 14) and supporting infrastructure. Its battery test chambers can cycle complete automotive battery packs with a useable volume of 23.1m3.

They test up to 1,100V, 2800A and up to 1,000kW continuous (1,200 kW peak). The chambers can simulate rapid temperature changes between -40°C and +90°C and humidity is controllable between 10% and 95%.

Customers are provided with a test report and post-test photography. Battery strip and inspection can also be conducted, as required, after the shock test. UTAC can manage battery disposal and transportation through an approved third party.

UTAC’s EV Battery Test Facility is operational 24 hours a day, 365 days a year.

UTAC UK battery lab

Battery Life and Performance Testing

UTAC tests to standards including ISO 12405 and GB/T 31484-2015.We conduct many tests to customer-specific standards.

Extensive battery safety systems are in place to minimise risks. The chambers within the Battery Test Facility are designed to contain a EUCAR hazard level 6 event and ensure safety during a hazard level 7 event.


Automation Software

Battery Cell and Module Performance and Life Testing

Tests are controlled using UTAC’s REPS automation software, which allows battery tests to be configured to customer requirements. The software also has extensive logging capabilities and almost unlimited storage for recording data whilst testing the life and performance of the battery. As well as running the test chambers, REPS can control the coolant flow and temperature for liquid cooled battery packs.

Customers are provided with test reports at the end of testing and are given daily updates on progress, which can include the previous day’s logged data.

UTAC can also manage battery disposal and transportation through an approved third party.

UTAC has a flexible facility for testing EV battery cells and modules.

Most testing is performed on Lithium-ion chemistries, but testing can be safely conducted on almost all chemistries within UTAC’s battery test laboratories.

For performance and life testing of battery cells, most test channels are rated at 5V/250A. However, these can be run in parallel for higher currents, for example two channels running in parallel allows testing at 5V/500A. Battery cell testing is conducted to a number of standards including IEC 62660 and QC/T 743.

UTAC tests the performance and life of battery modules in line with a range of standards including ISO 12405.

Safety systems are in place to minimise risks during battery testing. UTAC offers a wide range of battery abuse tests for cells, modules and full EV battery packs.
Customers are provided with test reports at the end of testing and are given daily updates on progress, which can include the previous day’s logged data.

Battery Strip and Inspection

After completing a battery test, UTAC’s skilled team safely strips them down to component parts, while measuring key parameters, such as distances, torques, voltages, and resistances. A detailed photographic record can also be provided.

A high-resolution video link allows real-time interaction. This can be especially useful in situations where the battery pack is damaged, making it difficult to specify in advance what is of interest.

UTAC conducts abuse testing of lithium ion batteries for applications including rail, aircraft, grid storage and electric vehicles, all of which can be followed up with battery strip and inspection.

Electrified Driveline Testing

UTAC performs electrified driveline testing in 1E, 2E and 3E configurations.

UTAC has developed significant electric vehicle test capabilities and can support large automotive electric driveline development programmes. High speed, torque and power can be catered for across the passenger car and commercial vehicle markets.

UTAC can run and manage the full range of tests outlined in ISO 16750 and LV124, giving its customers a ‘one-stop shop’ when it comes to completing a full design verification plan (DVP) for an electric drive system.

Test Facilities Specifications

The test facilities are modular in configuration, allowing maximum flexibility when putting together solutions for different test scenarios.

Single machines can be characterised, calibrated and tested for durability against a range of available input machines.

2E configurations with high-dynamic wheel hub output machines are capable of absorbing high torques and speeds while delivering class-leading accuracy in torque and power measurements.

HBM e-drive power analysers are used across the facilities and enable Electric Drive Unit (EDU) manufacturers to quantify efficiency losses through the electric drivetrain.  These analysers measure power from the DC BUS into the power electronics and the e-motor as multiphase AC / pulsed energy, and out to the mechanical drivetrain through the gear set. This gives UTAC’s customers unparalleled accuracy and high-frequency acquisition of EDU electrical dynamics.

Rig Configuration

Power to the DC bus power electronics on a 2E driveline testing rig is provided by scalable 300kW, 1000V, 1000A battery emulators – these systems can also be paralleled to provide more power to power electronics systems if needed.

The rigs can also be configured to run 3E configurations. The input machine of the EDU is replaced by ultra-dynamic synchronous machines.

For fatigue testing, the rigs can be configured to input high torque into a gear set and also shock loading into the wheel-end outputs of an EDU (kerb strike simulation).

Environmental enclosures can be placed around EDU systems to test thermal loading of the EDU and power electronics systems.

UTAC also caters for mechanical shock, vibration, water and dust ingress and NVH testing of EDU systems.

To complement UTAC’s test capabilities, a strip and rate facility in the UK provides access to highly specialised camera and lighting equipment. This is used to undertake post-mortem and post-test recording of test samples and their integral components.

Track Testing

UTAC offers a range of tracks in the UK, France, Finland (cold weather) and Morocco (hot weather) that have convenient EV charging capabilities (up to 500kW, 1000V/500A). Hydrogen (Fuel cell and ICE) vehicle testing is also supported.

Workshops and offices are also available for hire.

Read more

Train & Support

If you would like to know more about electromobility, do not hesitate to contact our subsidiary Train & Support and discover more than 60 training offers.

Know more


If you would like to know more about electromobility, please contact our team of experts. We support you in developing mobility worldwide.

Know more

With UTAC, choose turnkey solutions combining innovation, expertise and reliability.