Battery Abuse, Cycling and Durability Testing

Millbrook enables customers to: assess the performance of battery cells, modules and packs; determine pack performance during a crash event; and subject batteries to a range of environmental conditions.

Millbrook offers a range of UN 38.3 and all Reg 100 battery test capabilities.

Battery Abuse Testing

Millbrook routinely tests all major Lithium-ion chemistries and plans to expand this capability to cover most other chemistries in 2019.



  • Battery vibration testing
  • Battery mechanical crush, impact and shock testing
  • Thermal shock testing and battery cell, module and pack cycling
  • Drop testing
  • Immersion testing
  • Penetration testing
  • Fire resistance testing
  • Over dischange testing
  • Over charge testing
  • Over temperature testing
  • Short circuit testing


Battery abuse testing

Battery climatic cycling and battery durability testing

Battery Durability Testing

This part of Millbrook’s battery test capability is focused on life testing and functional validation (including life, power, internal resistance and BMS functionality) to standards including ISO 12405 and ISO 19453.

Millbrook has over 100 battery cell and 9 battery module and pack test cyclers. It is adding 12 new battery test chambers for cycling large automotive battery packs, which will be fully operational in 2019. This will provide a total of 30 pack cycler channels.

Millbrook routinely tests Li-ion cells, modules, packs and vehicles (class M1-M3 and N1-N3) and will consider other chemistries including Lithium-metal.


Battery test cells (packs):

  • 1,100V and up to 500kW per cell (max 750kW with reconfiguration)
  • Test area: 26.4m³

Battery cycler:

  • 500kW, 1,100V min, 1,400A
  • Voltage and current control accuracy <+/-0.03% FS
  • Can be operated as a single 500kW system or twin 250kW systems operating independent cycles
  • Scalable in 250kW steps to 750kW

Environmental chamber:

  • W 3.0m x L 4.0m x H 2.2m (26.4m³)
  • Operating temperature: -40°C to +90°C
  • 3K/min rate of cooling and heating
  • Humidity controllable from 10% to 95% r.h. from +5°C to +85°C
  • EUCAR Hazard Level 6

Battery conditioning:

  • Operating temperature: -45°C to +125°C
  • Control accuracy +/-1°C
  • 8kW heating power
  • 9kW cooling power
  • 40ltrs/min fluid flow rate


Data acquisition:

  • Up to 100 data channels, including a range of:
    • Voltage
    • Current
    • Temperature
    • Pressure
    • Flow

Remote access:

  • Secure staff and customer access to details of running tests
  • Secure communication between test facilities: data stream, camera and video conferencing


  • Palletisation of battery test trolley to allow test preparation outside the test cell to include:
    • Instrumentation
    • Fluid 
    • HV 
    • LV / CAN

Contact us now for more information on Millbrook's battery test capabilities and to book any of the facilities.

Download the full specification for battery abuse testing and battery durability testing.

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