White Paper: Test & Measurement
Shipped and Shocking: Battery Safety Beyond the Lab
SPONSORED BY: ![]()
Even after meeting UN38.3 and shipping regulations, batteries face risks in logistics, storage, and end use. Fires on highways, in recycling facilities, and on passenger aircraft highlight the dangers of mishandling, improper state of charge, and weak documentation. This white paper examines real-world incidents, regulatory requirements, and best practices to help manufacturers and logistics teams reduce downstream risks and strengthen safety across the battery supply chain.
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Overview
The white paper "Shipped and Shocking: Battery Safety in Logistics and Storage" by Element Materials Technology Group addresses the critical importance of battery safety in logistics and storage, particularly in the context of regulatory compliance and risk management. With a focus on the testing, inspection, and certification of batteries, the document outlines how rigorous testing processes are essential for ensuring the safety and reliability of battery products across various industries, including aerospace, transportation, and energy.
The paper emphasizes that testing is not merely a final step but an ongoing process that helps identify potential failure mechanisms at both the cell and pack levels. Emily Klein, the Lead Failure Analysis Engineer at Element, highlights the significance of understanding these failure mechanisms to improve product design and performance. By designing experiments that yield data-driven insights, the team aims to enhance safety and reliability in battery technology.
A key aspect of the document is the discussion of regulatory compliance, particularly the UN 38.3 testing requirements, which have become de facto mandatory in the U.S. due to their incorporation into regulations by the Pipeline and Hazardous Materials Safety Administration (PHMSA). The paper outlines the necessity for manufacturers to publish a Test Summary (TS) for lithium cells and batteries, detailing their physical attributes and compliance with safety standards. Non-compliance can lead to severe consequences, including fines, shipment delays, and reputational damage.
The white paper also addresses the evolving nature of safety testing, shifting from a checkbox mentality to a more refined approach that uncovers gaps in safety protocols. It discusses real-world incidents that underscore the importance of proactive safety measures and the need for continuous improvement in testing methodologies.
In conclusion, the document serves as a comprehensive guide for stakeholders in the battery supply chain, emphasizing the importance of rigorous testing, regulatory compliance, and a proactive approach to safety. By prioritizing these elements, the industry can work towards minimizing risks and ensuring that battery products are safe for consumers and the environment. The overarching goal is to make tomorrow safer than today through innovation and informed practices in battery technology.