DEKRA x Sphere: Redefining Battery Validation

Redefining Battery Validation

Battery validation is often time-consuming, and to remain competitive, manufacturers need faster and more efficient evaluations of their batteries. To address this, DEKRA and Sphere have partnered to redefine how battery cells are validated, enhancing their safety and accelerating their market introduction. We achieve this through a unique AI-based simulation service that supports battery cell validation. By using models trained on real battery data, we can accurately predict battery behaviour, such as ageing, across a range of conditions, including temperature variations and performance shifts.

A clear principle drives our purpose of redefining battery validation: smarter, faster, trusted.

Smarter: Leveraging AI and data analytics for fast and accurate battery behaviour.
Faster: Simulation helps reduce validation time, leading to earlier market introduction of battery products.
Trusted: Supported by reliable and validated physical test data conducted by experienced DEKRA technical experts.

Accelerating Battery Validation with AI Simulation, Data Analytics and Advanced Testing

We support customers in introducing their batteries to the market by optimising testing processes through the integration of Advanced Testing, Data Management, and AI-based Simulation during battery validation. Together, these services bridge innovation, regulation, and sustainability, enabling faster, more reliable battery-driven transformation across the mobility, energy, industry and commercial sectors.

To accelerate the validation, a significant amount of data is collected during laboratory testing, making data management a critical part of the process. Establishing a single source of truth with trustworthy, high-quality battery data is essential to ensure clarity and consistency. This involves a standardized approach to processing battery data, supported by automated data harmonization and data processing to reduce manual effort and eliminate errors.

Once harmonized, these data sets can be analyzed and used to create simulations tailored to each customer’s specific needs. These simulations leverage AI models specifically designed and trained to evaluate critical aspects of battery performance, including efficiency, and lifecycle behavior.

By combining real-world test data with advanced AI-driven modeling, we enable customers to optimize battery designs faster, reduce development risks, and accelerate time-to-market.

End-to-end Solutions Across The Battery Lifecycle

We support customers in ensuring battery safety and performance throughout the entire development cycle by combining cutting-edge simulation with robust physical testing. Our capabilities cover from early-stage cell innovation at Sphere’s Battery Technology Center in Germany, to the testing, validation, and certification of fully integrated battery systems for automotive, power tools, industrial applications and energy storage applications through DEKRA’s global network of laboratories. These strategically located laboratories are in Arnhem (Netherlands), Guangzhou, Shanghai-Jiading (Mainland China) and our newly opened Battery Test Centre in Klettwitz (Germany).

Together, DEKRA and Sphere Energy deliver end-to-end support throughout the entire battery development journey.

Our Services

Advanced Battery Testing

We offer advanced battery testing where battery cells are assessed under real-world conditions, beginning with benchmarking and characterization of electrical, thermal, and ageing performance.

These insights feed into broader module and pack testing, from electrical and thermal characterization to abuse and durability tests. The combination of physical testing with results obtained in accurate simulation cases, enables evaluating if batteries meet performance, safety, and regulatory requirements.

Smart Data Management

As every battery test generates a wealth of operational data, we offer customers a Smart Data Management system that captures, standardizes, and analyses these datasets to extract meaningful insights across testing cycles and battery generations. Developed by Sphere Energy, this platform enables trend tracking, traceability, and clarity, transforming data into a strategic asset for continuous improvement and informed decision-making throughout the product development and lifetime stages, which is highly valuable for reductions in development time and costs.

AI-Based Simulation for Batteries

In partnership with Sphere Energy, we offer a unique service to support battery cell characterization and validation using AI-based simulation. With the help of AI models trained using real battery data, we predict accurate battery behaviour across multiple conditions, including ageing, temperature, and performance shifts.

Our method enables fine-tuning the AI model based on customer-specific battery systems, allowing to reduce time and cost by generating synthetic data for all key performance and lifetime modalities. This allows rapid prototyping, faster iteration cycles, and improved decision-making for R&D and production teams.

Combining DEKRA's global expertise in testing and certification with Sphere's advanced AI and Data Science-based simulation, we provide a seamless end-to-end validation service to support customers throughout the entire development cycle of their batteries.

Our Scope

Our services cover various battery types, including:

Electric Vehicle (EV & HEV) batteries

Batteries used in electric vehicles and hybrid electric vehicles.

Stationary Energy Storage Systems (ESS)

Batteries used in the stationary energy storage systems (ESS).

Industrial & Consumer Batteries

Batteries used in manufacturing equipment, construction, robotics, electronics, power tools, home appliances, and more.

Our Battery Facilities

With a global network of state-of-the-art laboratories, DEKRA is equipped to validate, test, and certify batteries for today and tomorrow’s energy solutions.

DEKRA Battery Test Center – Germany

DEKRA Battery Testing Laboratory – Netherlands

DEKRA Battery Testing Laboratory – China

Sphere Battery Technology Center – Germany (Partner)