Battery Testing

Stress Engineering Services, Inc. (SES) offers battery safety and performance testing to various industry standards and has facilitated the development of standards by which batteries are tested. We provide expert battery testing services for clients across several applications and industries, including: Aerospace; Automotive; Grid Storage; Transportation; Aviation; Oil and Gas; Maritime; Medical; and Consumer Electronics.

Battery Testing Services

Our Battery Testing Services dig deep into the complex electrochemical/thermal system that constitutes a Lithium-ion Battery to provide answers to critical questions shared by both battery engineers and end users alike, including:

  • Which factors have the greatest influence on the probability and severity of a thermal runaway event?
  • How can thermal runaway propagation be mitigated using safety-focused module design?
  • What steps can be taken to improve the safety of LIBs during operation and transportation?

Thermal runaway propagation testing, containment testing, standards development testing, cycle life and performance testing and fire exposure resistance testing are all performed at our Testing Facility in Waller, Texas. This state-of-the-art test facility houses a wide array of equipment used to characterize the cells electrically, along with various chambers for environmental control, abuse testing, external fire testing, and gas analysis.


Battery Packaging Performance Test

Safety Testing Programs

In addition to testing to various industry standards, we are engaged in several unique battery safety testing programs developed in collaboration with our clients including:

  • Battery packaging characterization and safety assessment under off-nominal conditions
  • Multicell thermal runaway propagation studies
  • Cell-level assessment of thermal behavior at various state-of-charge
  • Charge retention studies at various state-of-charge
  • Research studies of grid storage systems


  Stress Blog:

Lithium-Ion Battery Safety Testing

Lithium-Ion Battery Safety Testing

Safety and Performance Criteria

Our battery testing capabilities provide our clients with the assurance that their battery systems meet and exceed safety and performance requirements before installation and commissioning potentially saving millions of dollars in recall or redesign costs in the process.  Our unique capabilities include:

  • Heat-to-vent/heat-to-thermal runaway
  • External short circuit
  • Thermal runaway propagation and containment testing
  • Mechanical abuse testing (nail penetration, crush, drop, shock, vibration testing)
  • Combined electrical and environmental/thermal cycling
  • Performance and abuse testing at high pressure/vacuums
  • Gas collection and analysis (GC)
  • Destructive Physical Analysis (DPA)
  • Standards testing
    • UN/DOT 38.3, RTCA DO-227a, DO-311a, UL 1642, UL 2054, UL 9540, UNECE R100, IEC
  • Fire exposure testing
  • Battery standards development
  • Highspeed monitoring of temperature, voltage, and pressure
  • Real-time multi-camera video capturing include infrared thermography
  • ITAR Testing
  • ISO 9001:2015 Compliant
  • Custom battery testing needs
  • Coupled electrochemical-thermal analysis using computational fluid dynamics (CFD) analysis

Contact Us

If you would like more information on Stress Engineering Services, please call us at 281.955.2900, or complete the following form and one of our representatives contact you shortly. For a complete listing of contact information, visit our Locations page.

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