Lithium cells and batteries can enter thermal runaway if damaged, overcharged or exposed to extreme conditions. UN 38.3 — set out in the UN Manual of Tests and Criteria, subsection 38.3 — defines a set of tests that a cell or battery must pass before it can be transported. Without a passing record and a published Test Summary, air, sea, road and rail carriers will not accept the shipment.
| Test | Condition | What it proves |
|---|---|---|
| T1 Altitude simulation | Storage at 11.6 kPa (simulated 15,000 m) for at least 6 hours | The cell does not leak or rupture at low pressure |
| T2 Thermal test | Cycling between +75 °C and −40 °C with defined dwell times | Integrity through rapid temperature change |
| T3 Vibration | Sinusoidal vibration swept across 7 Hz to 200 Hz and back, over several hours | Resistance to transport vibration |
| T4 Shock | Half-sine mechanical shock at defined peak acceleration | Survives handling shocks |
| T5 External short circuit | Terminals shorted at 55 °C until temperature stabilises | No fire or rupture under a short |
| T6 Impact / Crush | Impact for cells, crush for cells within batteries | Behaviour under mechanical abuse |
| T7 Overcharge | Charging beyond the specified limit | Protection circuit or cell tolerates overcharge |
| T8 Forced discharge | Cell forced into reverse polarity in a series string | No hazard under reverse charging |
Several tests are defined by elapsed time rather than effort — the thermal cycling in T2 alone spans multiple days, and the altitude and vibration tests each run for hours. That is why UN 38.3 typically takes 3–4 weeks end to end even when everything passes, and why rush options are limited.
Since 2020, manufacturers and distributors must make a UN 38.3 Test Summary available. It should include the cell and battery identification, the test laboratory, the test dates, a reference to each test performed and the results. Carriers, forwarders and customs authorities ask for this document routinely — having it ready prevents shipments being held.
No. UN 38.3 is a transport safety test regime required to ship lithium batteries. IEC 62133 is a product safety standard for the cell and battery design. Most battery projects need both.
Typically 3–4 weeks, because several tests are defined by elapsed time and cannot be compressed.
Yes, if the change affects chemistry, capacity, construction or the protection circuit. Cosmetic changes and packaging changes generally do not require retesting.
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