Understanding Lithium Battery Test Requirements & How CHEMTREC Simplifies Compliance

As the world celebrates National Battery Day this week, there has never been a more important time to understand the safety standards behind the power sources driving our modern lives. From portable electronic devices, electric vehicles, and back-up energy storage applications, lithium batteries are a dominant energy source for powering global innovation.
 

Their high energy density makes lithium batteries top performers, but they are not without their risks. In rare cases, lithium batteries can fail and enter thermal runaway – often resulting in generation of extreme heat, flame, projectiles, and evolution of flammable gases.

Why UN 38.3 Testing Matters

To help mitigate these risks, global regulators established a lithium battery testing protocol designed to expose lithium cells and batteries to conditions they may encounter during transportation, use, or storage. These tests can be found in the United Nations Manual of Tests and Criteria, Part III, Sub-Section 38.3 (often referred to as just the “UN 38.3 tests”). 

What is Included in the UN 38.3 Testing Protocol?

UN 38.3 consists of eight tests, commonly referred to as “T1 through T8”:

•    T1: Exposure to altitude changes
•    T2: Thermal Test (high heat/temperature cycling)
•    T3: Vibration
•    T4: Shock
•    T5: External short circuit
•    T6: Impact/crush
•    T7: Overcharge (for batteries only)
•    T8: Forced discharge (for cells only)
 

Generally, cells and batteries are considered to have passed the tests if they show no rupture, leakage, venting, disassembly, fire, or significant voltage drop when all the tests are completed under UN 38.3 requirements.

When a Battery Hasn’t Passed UN38.3

Lithium cells and batteries that have not been tested to the UN 38.3 standard can only be shipped under the more restrictive “prototype or low production run” regulations. 

•  “Prototype” cells and batteries are being transported for the purposes of testing, including but not limited to transport for UN 38.3 testing. 
•  “Low production run” cells and batteries are those being transported for use in their intended application (not testing related) and are subject to an annual production limit of 100 cells or batteries. 

Shipping prototype or low production run cells or batteries by highway, rail, and ocean often requires specialized packaging, formal dangerous goods transportation training, and complex shipping documentation. Shipping them by air is even more challenging. 

The shipper must obtain approval from the government of the country of origin (i.e., country where the battery is first loaded onto the aircraft), the country that approves the operator, and, if transporting to/from/within the United States, approval from U.S. Department of Transportation (DOT) is also mandatory. These approvals can take months, making air transport  of lithium batteries difficult. 

Every Design Must Have a Report – and a Test Summary!

Each lithium cell or battery design type must pass the UN38.3 tests. 

This includes:
•    Every new lithium cell design
•    Every new battery design (even if made from already tested cells)
Even minor modifications to a previously tested cell or battery design type may necessitate re‑conducting the UN 38.3 tests for the revised design.  

Once testing is complete:
•    Manufacturers must generate and retain a UN 38.3 test report for each design type. 
•    Downstream distributors and suppliers must also provide a UN 38.3 Test Summary Document to show that all shipped cells and batteries meet the standard. 

If your company manufactures or ships a wide range of lithium cells and batteries, managing a UN 38.3 Test Summary for each design type can quickly become overwhelming. Paperwork piles up, versions become difficult to track, and compliance risks grow as your product lineup expands. 

That’s exactly where CHEMTREC adds value, bringing order, efficiency, and confidence to a process that can otherwise consume valuable time and resources.

CHEMTREC Lithium Battery Test Summary Service

We help companies gather, organize, review, and maintain all required UN 38.3 Test Summaries so they’re readily available when requested. Our team streamlines the entire process, reducing administrative strain and giving you confidence that your compliance documentation is always ready when you need it. Learn more

Power Innovation Safely This National Battery Day

As lithium batteries continue powering the breakthroughs that define 2026 and beyond, the responsibility to manage them safely and compliantly only becomes more critical. CHEMTREC is here to equip organizations with the support and confidence they need.

If your company ships lithium cells or batteries, you are required to complete training based on 49 CFR Part 172, Subpart H - making now the perfect time to strengthen your compliance foundation, with our newest training bundle!

Purchase our NEW Training Bundle: Safe Transport of Lithium Batteries today. 

What’s included? One Hazmat General, Safety and Security Awareness Prerequisite Training and one Shipping Lithium Batteries and Cells Training. Save when you bundle – this package gives you the full value of the prerequisite Hazmat General, Safety and Security Awareness Training for FREE!

Let CHEMTREC manage your lithium battery compliance - so you can stay focused on building what’s next.