Battery development: FEV eDLP – World’s largest independent testing center

History: Increasing demand

Driven by the continuously growing need for high-voltage battery testing, FEV established a new, centralized test facility in 2019. The aim was to consolidate all development, validation, and endurance tests under one roof, resulting in the world’s largest and most advanced development and test center for battery modules and high-voltage battery systems.

FEV brings extensive experience in battery testing. Since 2008, electric and thermal endurance tests for battery cells, modules, and packs have been successfully performed for international customers at the FEV Trappes Test Center in France, a facility specialized in long-duration and endurance testing under realistic operating conditions.

In addition, FEV operates battery test infrastructure at multiple locations. In Aachen, Germany, dedicated test benches support cell and pack testing for pre-development and innovation projects. Additional battery cell test channels are available at FEV EVA in Munich and at FEV UK in Coventry, United Kingdom, enabling a broad spectrum of development and validation activities.

While the sites in Aachen, Munich and Coventry focus on development and functional testing, Trappes specializes in endurance and lifetime testing. Together, these locations form a comprehensive, globally connected battery testing network within the FEV Group.

Your engineering partner in battery development and testing

The high-voltage battery system is a key enabler of automotive electrification. It supplies energy to the vehicle’s high-voltage electrical architecture and drivetrain and represents the single largest contributor to the overall value chain of an electric vehicle.
To ensure readiness for series production, high-voltage batteries (HVB) must undergo comprehensive testing during early development and ramp-up phases. These tests are designed to validate performance, durability, and safety under realistic operating conditions.

Based on defined criteria such as mechanical stability, service life, and intrinsic safety, customized test programs are developed for each battery system. The scope and depth of testing are adapted to the maturity level of the development object, from early prototypes to near-production designs. The objective is to generate complete, validated test results that fully meet all functional, safety, and regulatory requirements for high-voltage battery systems.

Advantages: FEV eDLP – Our resources, your advantage

Almost 15.000 m² area
The world’s largest and most advanced development and test center for a wide range of battery modules and high-voltage batteries.
Experience since 2008
FEV has been successfully performing electrical and thermal endurance tests on battery cells, modules and packs for international customers since 2008.
Certification & accreditation
Certified to ISO 9001, ISO 14001, ISO 45001, ISO 50001 & TISAX. Accredited to: ISO 17025 DAkkS. For more details, please contact our sales department or use the contact form below.
All types of battery testing
Our highly skilled teams offer comprehensive electrical testing (performance and endurance), as well as environmental, mechanical, safety, and abuse tests.
Beyond automotive
In addition to the automotive industry, we support battery development and testing for non-road applications, aircraft, and stationary energy storage systems.

Test areas: Discover our versatile test areas

Vibration and shock testing

A 350 kN shaker is available for mechanical testing, enabling vibration and shock testing under highly dynamic load conditions. The system is equipped with a climate chamber allowing combined environmental and vibration testing in a controlled temperature range from –40 to +100 °C.
Beyond shaker-based tests, our climate chambers enable temperature cycling, thermal ageing and humidity testing, while salt spray chambers asses corrosion resistance and durability under aggressive environmental conditions.

The infrastructure is further enhanced by a multi-channel battery tester with capacities up to 1200 V, 1200 A and 500 kW, enabling dynamic electrical load profiles for comprehensive battery evaluation.

Overview: Our range of services

We offer all relevant test methods for vehicle drives and their components. If your requirements differ, please contact us to discuss tailored solutions.

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Durability testing based on FEV developed or customer-specific profiles
Electrical, thermal and mechanical aging (cycling & calendar aging)
Capacity, resistance and efficiency testing
Cold start, self-discharge and open-circuit voltage (OCV) measurement
Swelling force testing
Cooling performance & cooling system validation including thermal-resistance housing profiles and dew testing

Crush tests
Thermal propagation tests (e.g. nail penetration)
Overcharging, deep discharge, and short circuit tests (internal as well as external)
Fire resistance testing
Cooling & electrolyte leakage tests
Drop tests and underbody protection tests
Hammer hit and Overpressure tests

UN 38.3 transportation tests
Vibration and shock tests including thermal and electrical cycling
Climate and corrosion testing
Salt spray tests
IP-class tests (e.g. IPX6, IPX7, IPX9K)
Vacuum chamber & high altitude simulation for entire packs
Dust chamber & immersion tests
Thermoshock- & rock fall tests

Tear down on intact and damaged batteries
Disassembly and documentation
Benchmarking
Result reporting
Improvement workshops

Simulation of transport and handling events – our chambers allow simulation of real-world transport and handling conditions, including extreme events:

Vacuum, humidity and temperature changes (-40 to +80 °C)
Vibration & shock including during temperature changes and electrical cycling
Falling and starting

Test in the field of “usage”

Cleaning with high-pressure washers
Environmental exposure: immersion, water mist, corrosion & rock-fall simulation
Damaged cooling systems: overpressure testing in cooling system & loss of cooling fluid

Certificates:

ISO 9001 | ISO 14001 | ISO 45001 | ISO 50001 | TISAX Extended Prototype

Accredidation:

ISO 17025, German accredidation body (DAkkS)

Details:
For more information on the status and scope of all certifications and accreditations please contact your sales representative or use the contact form below.

test benches & Facilities:

Nearly 60 modern test benches and facilities

We offer comprehensive component testing for drivetrains and electromobility applications. To discuss your specific requirements, please use the contact form below.