EV Battery Testing Solutions

The Challenges of Leak Testing EV Batteries

EV battery packThe Electric Vehicle (EV) market is an emerging one. Requirements and specifications are still evolving, making it difficult for manufacturers of components like EV batteries to design processes and set test limits that will result in a consistent, high quality product. At the same time, stringent leak testing is a key element of EV battery production. All battery components – cells, modules, coolant systems and packs – must be leak tight in order to avoid customer inconvenience and even catastrophic failure.

When undergoing testing, battery components are especially sensitive to issues such as temperature change and barometric pressure fluctuation. It is also challenging to spot the smallest leaks in large volume parts like EV batteries used for commercial vehicles. Leak testing instrumentation requires the sensitivity, accuracy and traceability needed to address the new but critical requirements of EV battery testing.

Standard Leak Test Instrumentation for EV Battery Components

CTS has 35+ years’ experience in providing leak test solutions for the most demanding applications. We are now levering that experience into consulting with manufacturers in the EV market (cells, modules, cooling systems and packs) and delivering leak test services and instruments that help them understand, define and address their requirements. 

Factors like part size, leak rate, temperature and part expansion don’t have to hold up the launch of your EV battery when a scientific approach is taken to determine the best test method. We are already working with some of the top EV and automotive manufacturers and suppliers, offering innovative, cost effective solutions to those issues that keep EV battery test engineers awake at night. 
Sentinal 3520     Sentinel I28

CTS Sentinel 3520: A Proven Leak Tester for EV Batteries

The CTS Sentinel 3520 instrument is engineered with the precision, robustness and features needed to address a range of battery applications where things like ballooning and large volume tend to be issues. The 3520 offers the sensitivity required to accommodate the leak rates that battery manufacturers are working with as they narrow in on the right specifications for this new application.

Learn more about why manufacturers with complex leak test requirements are choosing the CTS Sentinel 3520.
large volume leak test image
See why the Sentinel 3520's speciality in large volume leak testing
makes it ideal for testing battery packs: Click here to view the full infographic


Sentinel I28: The Right Choice for Battery Cooling Circuits

The Sentinel I28 instrument supports differential pressure leak testing which is well suited for low volume and low leak rate parts such as cooling plates. For a full cooling circuit, the I28 provides a user-friendly, cost-effective solution with high performance to effectively execute the leak test.

Learn more about why the Sentinel I28 is the right instrument for leak testing battery cooling circuits. 

Considerations for Leak Testing Battery Components


  • Ensuring the integrity of the cells for the life of the product
  • Tracer gas is favored over air leak testing methods


  • Determining the leak rate of the module cooling circuit
  • No clear industry standard across manufacturers

Cooling Circuits:

  • Testing plates, tubes and complete cooling circuit with varying leak rates
  • Testing the validity of circuit connections

Battery Packs:

  • IP67 standards are typical, and IP69K for harsh environments
  • No clear industry standard across manufacturers

Additional Issues with Leak Testing EV Battery Packs

Of all the battery components, battery packs pose the most challenges to leak testing. Part size is an issue as it is more difficult to reliably test large volumes. Packs are prone to part expansion at unpredictable rates. Temperature and atmospheric pressure also impact the pressure in the parts, and when these fluctuate due to heating from a previous process or atmospheric changes, test results can be compromised.

The goal with all battery testing, including packs is cost-effectiveness, maximized cycle time, and a reliable, repeatable test with low gage R&R.

At CTS, we have the solutions and services our customers need to solve their leak test problems and meet these goals.
Contact us for your EV testing systems and equipment, and to learn more about how CTS can help with your EV battery testing needs.