For the energy transition and electromobility, batteries must be safe, reliable and powerful. At ZSW Ulm, we test battery cells, modules and complete systems under realistic and extreme conditions to ensure they are fit for purpose, have a long service life and are safe.
Our battery testing includes electrical, thermal and mechanical tests, as well as safety tests in the event of misuse or accidents. This enables us to provide reliable data on the quality, performance and safety of rechargeable batteries.
ZSW offers industry and academia a comprehensive battery testing service that provides reliable data on the performance, service life and safety of rechargeable batteries. This information facilitates the safe development of products, optimises service life and accelerates the market launch of new batteries.
Our battery testing centre has been in operation since 1998 and is now recognised as a testing laboratory throughout Europe.
Electrical battery testing involves checking the functionality of cells, modules and systems, measuring their performance and determining their expected service life under defined loads and environmental conditions.
The Centre for Solar Energy and Hydrogen Research Baden-Württemberg (ZSW) in Ulm is one of Europe's leading institutes for testing, characterising and validating modern battery technologies – from cells to battery systems.
There is a growing interest in combining electrical testing with mechanical stress testing.
In this context, measuring mechanical parameters such as force development during charging and discharging, volume changes (expansion and contraction) and vibration and resonance behaviour is becoming increasingly important.
This combination creates realistic test conditions that are crucial for ensuring the reliability and safety of modern battery systems.
We provide highly accurate analyses of the lifespan, performance and safety of commercial products and innovative prototypes through our battery testing. Our lifespan testing provides reliable predictions to support accelerated time-to-market for new batteries. Our laboratory offers comprehensive battery testing services to industry and academia, covering all applications, whether stationary or mobile.
To characterise the electrical properties, performance and ageing behaviour of battery cells and systems, they are subjected to comprehensive performance and service life tests at ZSW. Physical variables such as current, time, temperature and voltage are recorded and analysed, and this data is combined with information from battery management systems (BMS) via CAN or LIN bus interfaces.
In independent tests, our experts demonstrate that not only do battery systems meet all safety requirements, they also withstand a wide range of very demanding operating conditions in the automotive environment.
These include:
Energy storage systems that are also used for load management face additional stresses and challenges.
With Live Thermal Modelling, ZSW captures the thermal conditions of test specimens in real time, with both spatial and temporal resolution. This provides a reliable basis for evaluating complex battery cells, modules and systems. Depending on the test requirements, several hundred temperature sensors can be integrated, with the results visualized in three dimensions where required.
Based on this data, ZSW develops a tailored measurement, analysis and visualization concept for each test task, adapted to individual cells, modules, complete systems or specific contact points. Thermal anomalies, hotspots and critical areas can be identified at an early stage, including at contact points where mechanical or electrical weaknesses may occur.
Transparent visualization enables a reliable evaluation of the test setup and makes deviations immediately apparent, for example due to unsuitable sensor positions or implausible measurement values. This allows test results to be interpreted with confidence, tests to be adjusted as needed, and appropriate measures to be derived while testing is still in progress.
This approach reflects ZSW’s commitment to providing the right analysis for every testing challenge, with the highest level of technical expertise and quality.
When testing batteries, researchers and developers often face a recurring challenge: different cell types and formats require different, precisely adapted contacting solutions. Preparing cell cycling tests can therefore be complicated, time-consuming and prone to errors. Conventional test holders, which typically secure cells with screws, do not allow the contact pressure to be adjusted precisely and are often bulky by design – making them less practical for everyday laboratory work.
The new cell holder developed at ZSW Ulm addresses these challenges. Scientifically validated and already successfully tested in laboratory operation, it provides a simple, fast and reliable solution for securely fixing cylindrical battery cells.
It is modular, safe, fast and flexible – making it ideal for research, development and quality assurance.
Battery safety and the analysis of battery behavior under all conceivable conditions, including extreme scenarios, are of paramount importance for their safe use in everyday applications.
At our battery safety test center, we test individual cells as well as complete battery systems with capacities of up to 5 kWh. Functional safety tests are conducted in accordance with national and international standards or specific customer requirements. We can also develop and implement tailored test concepts for components, devices or complete systems under realistic conditions. This includes scenarios that go beyond standard test procedures to simulate extreme conditions or innovative applications.
Our facilities include modern test bunkers equipped with fire suppression systems, gas scrubbing systems, video monitoring and comprehensive data acquisition. These systems ensure safe and controlled testing conditions. Mechanical, thermal and electrical safety tests enable an in-depth analysis of battery behavior under realistic operating conditions.
The combination of many years of experience, advanced measurement technology and flexible testing capabilities provides reliable and meaningful test results. This gives manufacturers and users confidence that batteries can be operated safely, reliably, efficiently and over a long service life – from the prototype stage through to production-ready systems.
The ZSW Battery Test Centre in Ulm is one of Europe's leading facilities for developing and validating modern battery technologies. Over 100 scientists and engineers are employed here, working on solutions for electric mobility, stationary energy storage and sustainable energy systems.
For over 30 years, ZSW has conducted research across the entire battery value chain, from cell characterisation and safety testing to industry-scale production. A key component is the Battery Safety and Testing Centre, which has been in operation since 1998 and is recognised throughout Europe.
This is complemented by a research production line for large lithium-ion battery cells which has been operational since 2014, enabling manufacturing under industry-standard conditions.
With the “Powder-Up!” pilot plant, which has been operational since 2024, ZSW has also bridged an important gap between research and application. It enables the scaled-up production of innovative cathode materials and their precursors in quantities of up to 100 kilograms.
