Abuse testing

Abuse testing and battery safety: A comprehensive, tailor-made offering

Abuse and safety testing makes it possible to analyze the behavior of your batteries beyond their operating limits, identify risks, and demonstrate compliance with the strictest regulatory and standard requirements, including certification according to specific frameworks.

Thanks to our comprehensive approach, we support our clients with all battery challenges throughout their entire development and validation cycle, from the cell level to the complete vehicle.

What is an abuse test?

An abuse test consists of subjecting a battery to extreme conditions (thermal, electrical, mechanical, environmental), far beyond normal operating use, in order to evaluate its behavior, reactions, and safety level.

These tests help identify failure modes, prevent risks, and ensure that batteries comply with the strictest regulatory and industrial requirements.

Through strict protocols and specialized equipment, the objective is to simulate real or extreme conditions (temperature, cycling, etc.) in order to validate the compliance and performance of energy storage solutions. This approach is essential for meeting the energy challenges of tomorrow.

Tailor-made abuse and safety testing adapted to all your battery challenges

Drawing on its expertise and multiple testing platforms, SERMA performs a wide range of tests on cells, modules, battery packs, and complete vehicles under particularly severe conditions.

Mechanical tests

Static Crush

Dynamic Crush

Nail penetration

Drop

Impect

Vibration

Mechanical shock

Electrical tests

Overcharge

Overdischarged

Specific cycling

Internal and external circuit

Thermal tests

Thermal propagation (immersion possible)

Fire

Overtemperature

Thermal stability

Thermal shock

Instrumentation

Internal instrumentation of packs or modules (materials, thermocouples, voltage measurements)

Configuration and acquisition of BMS signals (Vector, Inca, CANoe)

Leak testing

Gas analysis, emanations

Identification and quantification

Post mortem analysis

From battery pack to cell

Electronic components

Visual and electrical inspection

Comprehensive and customized validation plans to address all your battery challenges

Every project is unique. SERMA designs fully customized test campaigns and supports you in developing the most appropriate and comprehensive validation plan for your needs.

Adaptation to technical and regulatory requirements
Complete validation plans
Mobilization of multiple test platforms and state-of-the-art equipment
External testing carried out with trusted partners when required

Comprehensive support for the development of your battery products

Beyond testing, SERMA acts as a technical partner throughout the entire development cycle of your battery products, from the earliest technical orientations to market launch.

Technological support

Architecture selection: cell, module, pack, BMS

Mechanical shock

Risk analysis

Specification review

Technological review

Performance evaluation (electrical, abuse, environmental testing)

Supplier and manufacturer audits

Technical training

Electronic boards

Battery chemistry

Battery safety

Support for certification and homologation

The tests carried out by SERMA provide a solid foundation for your certification and homologation processes.

Standards covered

ECE R100 (ISO 17025)
UN 38.3
UL 1642
IEC 62133, IEC 62619
DO-227, DO-311
KMVSS
SAE J2464
GBT314, GB 38031

Leading industrial capabilities

SERMA continues to invest sustainably to support the growth of electric mobility and other applications linked to the energy transition.

While many industrial players are slowing down their investments, SERMA has chosen the opposite strategy: continuing ambitious investments in e-mobility.

With the opening of a new 5,000 m² site dedicated to abuse testing and battery safety, SERMA confirms its role as a driver of French technical excellence serving the energy transition and european sovereignty.

Fully operational since August 2025, this site enables abuse testing on cells, modules, and battery packs up to 150 kWh, as well as on complete vehicles. It is equipped to perform a wide range of extreme tests, making it one of the most advanced centers in Europe.

SERMA: a trusted partner for all your battery challenges

We support our clients with all their battery challenges throughout their development and validation cycle, from the cell level to the complete vehicle.

Thanks to his unique expertise and testing capabilities, SERMA offers a comprehensive, reliable approach fully adapted to today’s industrial challenges.

Our battery expertises